Ceiling systems

ABSTRACT

A ceiling system in one embodiment includes an overhead support grid comprised of a plurality of intersecting grid support members and a ceiling tile mountable to the grid. Retaining clips support the ceiling tile from the grid which may be concealed from view. The retaining clips each include a cavity that receives a grid support member and a pair of resilient mounting elements configured to lockingly engage a support member. The mounting elements are laterally movable in response to inserting the support member into the cavity of the retaining clip. In one embodiment, the movable elements include locking tabs which create a snap-fit interlock with the grid support member for securing the ceiling tile to the grid.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 15/169,103 filed May 31, 2016, which is acontinuation of U.S. patent application Ser. No. 14/423,817 filed Feb.25, 2015 and issued as U.S. Pat. No. 9,353,522, which is a U.S. nationalstage application under 35 U.S.C. § 371 of PCT/US2013/058015 filed Sep.4, 2013, which claims the benefit of U.S. Provisional Patent ApplicationNo. 61/696,424 filed Sep. 4, 2012.

The present application is also a continuation-in-part of U.S. patentapplication Ser. No. 15/420,440 filed Jan. 31, 2017, which is acontinuation of U.S. patent application Ser. No. 15/163,042, filed May24, 2016 and issued as U.S. Pat. No. 9,556,613.

The present application is also a continuation-in-part of U.S. patentapplication Ser. No. 14/661,413, filed Mar. 18, 2015.

The foregoing listed applications are incorporated herein by referencein their entireties.

FIELD OF THE INVENTION

The present invention relates to ceiling systems, and more particularlyto ceiling systems having a concealed support grid enabled by aretaining clip system.

BACKGROUND OF THE INVENTION

One type of ceiling system includes ceiling panels or tiles that areinstalled in a support grid which may be suspended from or directlyinstalled to a suitable overhead building support structure. Suchceiling systems may be designed to partially or completely conceal thesupport grid from view.

An improved ceiling system with concealed support grid is desired.

As additional background, numerous types of suspended ceiling systemsand methods for mounting ceiling panels have been used. One type ofsystem includes a suspended support grid including an array ofintersecting grid support members configured to hang a plurality ofindividual ceiling panels therefrom. It is desirable in some cases toconceal the support grid for providing the appearance of a monolithicceiling. It is further desirable to apply a facing scrim or sheet to thebottom surface of the ceiling panels for concealing the joints betweenthe ceiling panels.

As additional background, a number of different materials have been usedfor creating seamless ceilings having a monolithic appearance. One suchmaterial is drywall. Drywall or wall board panels are surface mounted toa support surface or grid formed of wood or metal which are affixed toan overhead building structure to support the panels. Panels are affixedto the grid using fasteners. Highly visible joints formed betweenadjoining panels typically have relatively wide gaps which must be tapedand spackled with drywall joint compound to cover the joints andfastener heads. This process is time consuming and expensive generallyinvolving several iterations of spackling and sanding to achieve asmooth finish to conceal the joints. Furthermore, drying time must beallowed between coats of joint compound before sanding. The ceilinginstallation may take as long as five days in some cases and requirescompletion by skilled craftsman which increases installation costs. Thefinished joints and drywall are only now ready for applying a finishcoat or paint.

The foregoing drywall ceiling installation also requires attachment ofthe ceiling panels to a rigid support surface or grid. Such monolithicceiling systems may not always be suitable for attachment to suspendedgrid support systems, thereby limiting the number of applications inwhich drywall may be used. Moreover, drywall cannot deliver comparableacoustical performance to other ceiling materials such as acousticalceiling tiles or panels which many times is desired in occupied spaces.

An improved monolithic ceiling system is therefore desired.

SUMMARY OF THE INVENTION

The present invention provides a ceiling system in which individualceiling elements may be mounted to overhead support members in a secureand stable manner. In one embodiment, without limitation, a speciallyconfigured retaining clip is provided that is mountable in a track-likemounting system formed in the ceiling tile comprised of a plurality ofelongated channels. The retaining clips and channels permit the ceilingtiles to be installed in a manner that conceals the support grid fromview. Advantageously, the shape of ceiling tiles that may be used is notrestricted by the arrangement and pattern of the grid support members,as further described herein,

According to an exemplary embodiment, a ceiling system includes alongitudinally-extending grid support member mountable from an overheadstructure, a ceiling tile including a mounting channel extending atleast partially between first and second opposing peripheral sides ofthe ceiling tile, and a retaining clip slideably disposed in themounting channel of the ceiling tile. The retaining clip includes a pairof opposing and resiliently deformable mounting elements. The mountingelements are spaced apart to define a cavity configured to receive thegrid support member at least partially therein. The mounting elementsare laterally spreadable in response to inserting the grid supportmember into the cavity of the retaining clip, wherein the retaining clipis configured to lockingly engage the grid support member when in alocked position fully inserted into the cavity of the retaining clip forsecuring the ceiling tile to the grid support member. The grid supportmember is concealed from view beneath the ceiling tile.

According to another exemplary embodiment, a retaining clip attachableto a grid support member of a ceiling system is provided for supportinga ceiling tile. The retaining clip includes a mounting flange configuredfor attachment to the ceiling tile, and a pair of opposing resilientlydeformable upright mounting wings configured for attachment to the gridsupport member. The mounting wings extend upwards from the mountingflange and are spaced apart to define an upwardly open cavity configuredto receive the grid support member at least partially therein. Themounting wings are laterally deformable between undeflected anddeflected positions in response to inserting the grid support memberinto the cavity of the retaining clip. The mounting wings includelocking tabs which lockingly engage the grid support member when in amounted position inside the cavity of the retaining clip.

A method for mounting a ceiling tile to a grid support member of aceiling system is provided. The method includes: providing a gridsupport member mountable from an overhead support structure; providing aceiling tile including a horizontally elongated mounting channel, thechannel being open through a top surface of the ceiling tile; slideablyinserting a retaining clip into the mounting channel through aperipheral side of the ceiling tile; sliding the retaining clip to adesired mounting position; vertically aligning an open cavity of aretaining clip with the grid support member; inserting the grid supportmember into the cavity of the retaining clip; laterally displacing apair resiliently deformable locking tabs positioned in the cavity withthe grid support member; and lockingly engaging the locking tabs withthe grid support member for securing the ceiling tile to the gridsupport member.

A ceiling system is provided which conceals the ceiling support grid andceiling panel joints. The joints may be concealed with overlapping fieldcut facings or scrims forming seams between adjoining facings which arelaterally offset from the joint. A double-cut seam may be made in thefield creating tight seams between the facings with no appreciable gaps.

To achieve the foregoing seam arrangement, in one embodiment the ceilingpanels in their factory-supplied, pre-installed condition may be shippedto the field installation site with a pre-attached facing sheet which isadhesively bonded to only a central region on the bottom surface of theceiling panel body (i.e. surface which will be visible and facingtowards the room below the ceiling system). The perimeter portions ofthe facing sheet on all sides are not bonded to the annular peripheralregion on the bottom surface of the panel body surrounding the centralregion. In one implementation, the facing sheet extends beyond at leastone first peripheral edge of the ceiling panel forming a cantileveredflap. The facing sheet does not extend beyond the opposite peripheraledge of the panel in one embodiment. Each ceiling panel may have thisfacing arrangement.

During field installation, the facing sheet flap of the first ceilingpanel overlays a peripheral edge and perimeter portion of an adjoiningsecond ceiling panel. This creates a double thickness of unboundedfacing sheets which may then be severed along a cut line to form a seambetween the mating facing sheets of each panel. Following the seamformation, the unsecured perimeter portions of the two adjoining facingsheets adjacent to the ceiling panel joint may then be adhesively bondedto the peripheral portions of the ceiling panels with a field appliedand/or activated adhesive to complete the installation. In someembodiments, an inactivated adhesive may be pre-applied in the factoryto the annular peripheral region of the bottom surface of each ceilingpanel. The adhesive may be activated in the field via a heat gun,ultraviolet radiation, application of pressure, or other means dependingon the type of adhesive used. Advantageously, the present ceiling systemdoes not require complete installation of the facing sheets in the fieldwhich are prone to misalignment problems. The factory partiallypre-installed facing sheets ensure proper orientation and layout of thefacings with respect to each panel while the unsecured perimeterportions allow field cutting and adjustment of seams between facingsheets.

In one embodiment, a ceiling system includes: a longitudinally extendinggrid support member including a bottom surface; a first and secondceiling panel mounted below the grid support member, each ceiling panelincluding an acoustic panel body having a top surface, opposing bottomsurface defining a horizontal plane, plurality of peripheral edgesextending therebetween defining a perimeter, a central region of thebottom surface spaced inwards from the peripheral edges, and an annularperipheral region of the bottom surface surrounding the central regionand lying between the central region and the peripheral edges; alongitudinally-extending joint formed between adjoining first peripheraledges of each of the first and second ceiling panels; a first facingsheet adhered to the central region of the first ceiling panel with afactory-applied adhesive layer, and an annular perimeter portion of thefirst facing sheet being un-adhered to the peripheral region of thefirst ceiling panel adjacent to the joint; wherein the perimeter portionof the first facing sheet adjacent to the joint extends laterallyoutwards beyond the first peripheral edge of the first ceiling panelforming a first cantilevered flap, and the perimeter portion of thefirst facing sheet opposite the joint does not extend beyond a secondperipheral edge of the first ceiling panel opposite the first peripheraledge; a second facing sheet adhered to the central region of the secondceiling panel with a factory-applied adhesive layer, and an annularperimeter portion of the second facing sheet being un-adhered to theperipheral region of the second ceiling panel adjacent to the joint;wherein the perimeter portion of the second facing sheet adjacent to thejoint does not extend beyond the first peripheral edge of the secondceiling panel, and the perimeter portion of the second facing sheetopposite the joint extends laterally outwards beyond a second peripheraledge of the second ceiling panel opposite the first peripheral edgeforming a second cantilevered flap; wherein the first cantilevered flapof the first facing sheet extends across the joint to the second panelsuch that the cantilevered flap is positioned on the peripheral regionof the second ceiling panel.

In one embodiment, a factory-fabricated ceiling panel in a conditionbefore installation includes: a rectilinear acoustical panel bodycomprising a top surface and a bottom surface; a first panel edge and anopposing second panel extending between the top and bottom surfaces; athird panel edge and an opposing fourth panel extending between the topand bottom surfaces, the first panel edge and the second panel edge eachbeing perpendicular and adjacent to the third and fourth panel edges; aperimeter defined by the first, second, third, and fourth panel edges;the bottom surface of the panel body comprising a central region spacedinwards from the peripheral edges and an annular peripheral regionsurrounding the central region, the annular peripheral region extendingbetween the central region and the first, second, third, and fourthperipheral edges; a rectilinear facing sheet adhered to the centralregion of the bottom surface with a factory-applied adhesive layer,wherein an annular perimeter portion of the facing sheet is not adheredto the bottom surface of the acoustical panel body along the annularperipheral region of the bottom surface of the panel body; wherein thefacing sheet along the first panel edge extends outwards beyond thefirst panel edges forming a cantilevered facing flap; and wherein thefacing sheet along the second panel edge does not extend outwards beyondthe second panel edge.

A method for installing a ceiling system is disclosed. The methodincludes: providing first and second ceiling panels to a jobsite, eachpanel in a factory supplied condition including an acoustic panel bodyhaving a top surface, opposing bottom surface, plurality of peripheraledges extending therebetween defining a perimeter, and a facing sheetadhered to a central region of bottom surface with a factory-appliedadhesive, the facing sheet being un-adhered to an annular peripheralregion of the bottom surface surrounding the central region, wherein thefacing sheet includes a cantilevered flap extending beyond a firstperipheral edge of the panel body, and the facing sheet includes anun-adhered perimeter portion in the peripheral region which does notextend beyond a second peripheral edge of the panel body opposite thefirst peripheral edge; positioning the first and second ceiling panelsbeneath a longitudinally-extending grid support member; abutting thefirst peripheral edge of the first ceiling panel with the flap of facingsheet against the second peripheral edge of the second ceiling panelwithout the flap of facing sheet, thereby forming a joint; locating theflap of the first ceiling panel over the peripheral region of the secondceiling panel; overlapping the flap of the first ceiling panel with theun-adhered perimeter portion of the facing sheet of the second ceilingpanel in the peripheral region of the second ceiling panel, therebyforming a double thickness of facing sheets; cutting through the doublethickness of facing sheets along a line to create an abutment seam,wherein an end segment the flap and an end segment of the un-adheredperimeter portion of the facing sheet of the second ceiling panel in theperipheral region are severed; removing the end segments of the flap andfacing sheet, thereby leaving remaining portions of the flap and theun-adhered perimeter portion of the facing sheet of the second ceilingpanel in the peripheral region; and adhering the remaining portions ofthe flap and the un-adhered perimeter portion of the facing sheet of thesecond ceiling panel to the peripheral region of the second ceilingpanel; wherein the joint between the first and second ceiling panels isconcealed by the facing sheet of the first ceiling panel.

A faced ceiling system is provided which conceals the ceiling supportsurface or grid with ceiling panels having specially configuredperipheral edges that overlay the bottom surface or face of the gridsupport members. The ceiling panels in certain embodiments may includeedge portions configured to mount to and conceal the exposed ceilingsupport surface or grid faces. In certain non-limiting embodiments, theceiling panels may be acoustical tiles or panels.

In one embodiment, the ceiling system includes ceiling panels having acomposite peripheral hybrid edge detail including a combination of atongue-and-groove and shiplap configurations. The hybrid edges ofadjoining panels are configured to both interlock via thetongue-and-groove portion of the edge detail and hide the ceiling panelsupport surfaces or grid faces via the shiplap portion of the edgedetail.

The ceiling panels may be perimeter mounted to the support surface orgrid. In one implementation, lateral extensions of the ceiling paneldefine an upper shiplap edge profile and mounting flanges for directsurface mounting of the ceiling panel to and hiding the ceiling supportsurface or grid. When the panels are assembled together in the ceilingsystem, a lower shiplap edge profile formed on the peripheral edge ofadjoining panels in turn conceals the mounting flanges, thereby hidingany exposed fastening elements that may be used to mount the ceilingpanel to the support surface or grid. Advantageously, less than thetotal number of peripheral edges of the ceiling panel need to be affixedto the support surface or grid in some embodiments for properlysupporting the ceiling panel; the remaining edges being supported by thetongue-and-groove interlock formed with adjoining panels. This savesboth installation time and fastener costs.

In one embodiment, a ceiling system includes a ceiling support structurehaving a downward facing support surface, and a plurality of ceilingpanels attached to the ceiling support structure. The ceiling panelseach have a top surface facing the ceiling support structure, anopposing bottom surface, and a plurality of peripheral edges extendingbetween the top and bottom surfaces. A pair of adjoining first andsecond ceiling panels is mutually engaged along first and second matingperipheral edges respectively, the first and second peripheral edgeseach having a hybrid edge detail including a tongue-and-groove portionand a shiplap portion. The shiplap portion of the first ceiling paneldefines a laterally extending mounting flange attached to the ceilingsupport structure. The shiplap portion of the second ceiling panelcovers the mounting flange of the first ceiling panel. Thetongue-and-groove portions of the first and second ceiling panels areinterlocked, wherein the second peripheral edge of the second ceilingpanel is supported via the tongue-and-groove interlock with the firstceiling panel.

In one embodiment, a ceiling panel with hybrid edge detail includes abody including a top surface, a bottom surface, opposite first andsecond longitudinal sides extending between the top and bottom surfaces,and opposite third and fourth lateral sides extending between the topand bottom surfaces. The first longitudinal side has a first peripheraledge including a shiplap portion and a tongue-and-groove portion. Thethird lateral side has a third peripheral edge including a shiplapportion and a tongue-and-groove portion. The shiplap andtongue-and-groove portions of the first and third peripheral edges arearranged to engage complementary configured shiplap andtongue-and-groove portions of adjoining ceiling panels for forming aninterlocked ceiling system.

A method for concealing a ceiling support structure is provided. Themethod includes: providing a plurality of ceiling panels each having atop surface and an opposing bottom surface, the panels each havingopposing first and second peripheral sides, the first peripheral sidehaving a hybrid edge detail comprising a tongue-and-groove feature and alaterally extending shiplap feature adjacent the top surface, the secondperipheral side having a hybrid edge detail comprising atongue-and-groove feature and a stepped shiplap feature; attaching thefirst ceiling panel to the ceiling support structure; engaging thetongue-and-groove of the second peripheral side of a second ceilingpanel with the tongue-and-groove feature of the first peripheral side ofthe first ceiling panel; and engaging the stepped shiplap feature of thesecond peripheral side of the second ceiling panel with the laterallyextending shiplap feature of the first peripheral side of the firstceiling panel; wherein the second peripheral side of the second ceilingpanel is supported by first peripheral side of the first ceiling panel.

After installation of the ceiling panels, a final facing may beinstalled to ceiling panels to further conceal the exposedpanel-to-panel joints in furtherance of creating a monolithic ceilingappearance. In one embodiment, the facing may be installed in the field(i.e. jobsite) to cover a plurality of installed or hung ceiling panels.This type facing system is distinguishable from facing materials whichare sometimes applied to the exposed bottom surfaces of a single panelor tile at the factory.

In one embodiment, a faced ceiling system includes a ceiling supportstructure, and a plurality of ceiling panels attached to the ceilingsupport structure. The ceiling panels each have a width, a length, a topsurface facing the ceiling support structure, an opposing bottom surfacefacing an interior space below the ceiling panels, and a plurality ofperipheral edges extending between the top and bottom surfaces. Aplurality of joints is formed between mating peripheral edges ofadjoining ceiling panels. A final facing is supported by the bottomsurfaces of at least two ceiling panels; the facing covering at least aportion of the at least two ceiling panels and the joint formedtherebetween to conceal the joint. The facing has a width larger than atleast one of the width and length of the ceiling panels.

In some implementations, the peripheral edges of the ceiling panels havea hybrid edge detail including a tongue-and-groove portion and a shiplapportion. The tongue-and-groove portions between mating peripheral edgesof adjoining ceiling panels are interlocked. The shiplap portionsbetween mating peripheral edges of adjoining ceiling panels comprise anupper shiplap feature on one ceiling panel and a lower shiplap featureon the mating ceiling panel engaging the upper shiplap feature. In oneembodiment, the facing is adhesively bonded to the ceiling panels. Insome embodiments, the bottom surfaces of the panels may be treated toprepare the surfaces for adhesive bonding.

In another embodiment, a ceiling system with field-applied facingincludes a grid support system comprising a plurality of orthogonallyintersecting longitudinal and lateral grid support member defining anarray of grid openings, and a plurality of ceiling panels attached tothe grid support system. Each ceiling panel includes a pair of opposedlongitudinal peripheral edges and a pair of opposed lateral peripheraledges. Joints are formed between each ceiling panel and matinglongitudinal and lateral peripheral edges of adjoining ceiling panels.The peripheral edges of the ceiling panels have a hybrid edge detailincluding a tongue-and-groove portion and a shiplap portion. Thetongue-and-groove portions between mating peripheral edges of adjoiningceiling panels are interlocked. The shiplap portions between matingperipheral edges of adjoining ceiling panels comprise an upper shiplapfeature on one ceiling panel and a lower shiplap feature on the matingceiling panel engaging the upper shiplap feature. A final facing sheetof material is adhesively bonded to bottom surfaces of a plurality ofceiling panels, wherein the facing has a continuous extent in at leastone direction covering and concealing a plurality of joints betweenadjoining ceiling panels.

A method for facing a ceiling system is provided. The method includes:mounting an orthogonal array of ceiling panels to ceiling supportstructure, each ceiling panel including top and bottom surfaces, a pairof opposed longitudinal peripheral edges, and a pair of opposed lateralperipheral edges, the peripheral edges of the ceiling panels having ahybrid edge detail including a tongue-and-groove portion and a shiplapportion; forming a plurality of longitudinal joints between laterallyadjoining peripheral edges of the ceiling panels; and bonding a finalfacing to the bottom surfaces of the ceiling panels, wherein the facinghas a continuous extent in at least one direction covering andconcealing the plurality of the longitudinal joints. In one embodiment,the method further comprises applying a surface treatment to the bottomsurfaces of the ceiling panels before bonding the final facing. In oneembodiment, the bonding step comprises applying an adhesive layer to thetreated bottom surfaces to bond the final facing to the ceiling panels.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the exemplary embodiments of the present invention willbe described with reference to the following drawings, where likeelements are labeled similarly, and in which:

FIG. 1 is a perspective view of a ceiling tile retaining clip for use ina ceiling system according to the present disclosure;

FIG. 2 is a side elevation view thereof;

FIG. 3 is an end elevation view thereof;

FIG. 4 is top plan view thereof;

FIG. 5 is a top perspective view of a ceiling tile with retaining clipsof FIG. 1 mounted therein;

FIG. 6 is a side elevation view thereof;

FIG. 7 is an enlarged detail VII taken from FIG. 6;

FIG. 8 is an exploded top perspective view of an unassembled ceilingsystem including grid support members forming a support grid, retainingclips, and a ceiling tile;

FIG. 9 is an exploded top perspective view thereof with the retainingclips installed in mounting channels formed through the top of theceiling tile;

FIG. 10 is an enlarged detail X taken from FIG. 9;

FIG. 11 is a top perspective view the fully assembled ceiling systemwith the ceiling tile mounted to the grid support members using theretaining clips;

FIG. 12 is a side elevation view thereof;

FIG. 13 is an enlarged detail XIII taken from FIG. 12;

FIG. 14 is an enlarged detail XIV taken from FIG. 13; and

FIG. 15 is an end elevation view of the grid support member.

FIG. 16 is a side elevation cross-sectional view of a ceiling systemaccording to the present disclosure comprising a grid support member andceiling panels with peripheral edges forming a butt joint therebetween;

FIG. 17 is a side elevation cross section view of one of the ceilingpanels of FIG. 16;

FIG. 18 is a top plan view of the ceiling panel;

FIG. 19 is a bottom plan view thereof;

FIG. 20 is a top perspective view thereof;

FIG. 21 is a bottom perspective view thereof;

FIG. 22 is a bottom perspective view of the grid support member;

FIGS. 23-27 are side elevation cross-sectional views illustratingsequential steps in a method for installing the ceiling system of FIG.16 to conceal the joint formed between two ceiling panels;

FIGS. 28-31 are bottom plan views illustrating sequential steps in amethod for assembling an array of ceiling panels prior to cutting andtrimming the facing sheets on the bottom surfaces of the panels; and

FIG. 32 is a side elevation cross sectional view showing an alternativeconstruction of ceiling panels with peripheral edges having a hybridedge detail forming an interlocked joint therebetween.

FIG. 33 is a perspective view of a ceiling panel support structure inthe form of a suspended support grid formed by intersecting longitudinaland lateral grid support members;

FIG. 34 is a side cross-sectional view of intersecting longitudinal andlateral grid support members;

FIG. 35 is a bottom plan view of a ceiling panel with hybrid edge detailaccording to the present disclosure;

FIG. 36 is a side elevation view thereof;

FIG. 37 is bottom perspective view thereof;

FIG. 38 is a top perspective view thereof;

FIG. 39 is a side partial cross-sectional view of a ceiling system withceiling panels having the hybrid edge detail;

FIG. 40 is an enlarged detail of one of the joints between adjoiningceiling panels in FIG. 7;

FIG. 41 is an exploded view thereof with the grid support member showingthe hybrid shiplap and tongue-and-groove edge details of the panels;

FIG. 42 is an exploded bottom plan view of a ceiling panels showing onenon-limiting embodiment of an assembly or installation sequence;

FIG. 43 is a bottom plan view showing the assembled ceiling panels;

FIG. 44 is a side elevation view of a ceiling panel with hybrid edgedetail according to the present disclosure having a field applied finalfacing system; and

FIGS. 45-47 are bottom plan views of the faced ceiling system of FIG. 44showing sequential steps in attaching the facing system to the ceilingpanels.

All drawings are schematic and not necessarily to scale. Parts given areference numerical designation in one figure may be considered to bethe same parts where they appear in other figures without a numericaldesignation for brevity unless specifically labeled with a differentpart number and described herein.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The features and benefits of the invention are illustrated and describedherein by reference to exemplary embodiments. This description ofexemplary embodiments is intended to be read in connection with theaccompanying drawings, which are to be considered part of the entirewritten description. In the description of embodiments disclosed herein,any reference to direction or orientation is merely intended forconvenience of description and is not intended in any way to limit thescope of the present invention. Relative terms such as “lower,” “upper,”“horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and“bottom” as well as derivative thereof (e.g., “horizontally,”“downwardly,” “upwardly,” etc.) should be construed to refer to theorientation as then described or as shown in the drawing underdiscussion. These relative terms are for convenience of description onlyand do not require that the apparatus be constructed or operated in aparticular orientation. Terms such as “attached,” “affixed,”“connected,” “coupled,” “interconnected,” and similar refer to arelationship wherein structures are secured or attached to one anothereither directly or indirectly through intervening structures, as well asboth movable or rigid attachments or relationships, unless expresslydescribed otherwise. Accordingly, the disclosure expressly should not belimited to such exemplary embodiments illustrating some possiblenon-limiting combination of features that may exist alone or in othercombinations of features.

As used throughout, ranges are used as shorthand for describing each andevery value that is within the range. Any value within the range can beselected as the terminus of the range. In addition, all references citedherein are hereby incorporated by referenced in their entireties. In theevent of a conflict in a definition in the present disclosure and thatof a cited reference, the present disclosure controls.

Multiple inventive concepts are described herein and are distinguishedfrom one another using headers in the description that follows.Specifically, FIGS. 1-15 are relevant to a First Inventive Concept,FIGS. 16-32 are relevant to a Second Inventive Concept, and FIGS. 33-47are relevant to a Third Inventive Concept. These Inventive Conceptsshould be considered in isolation from one another. It is possible thatthere may be conflicting language or terms used in the description ofthe First through Third Inventive Concepts. For example, it is possiblethat in the description of the First Inventive Concept a particular termmay be used to have one meaning or definition and that in thedescription of the Second Inventive Concept the same term may be used tohave a different meaning or definition. In the event of such conflictinglanguage, reference should be made to the disclosure of the relevantInventive Concept being discussed. Similarly, the section of thedescription describing a particular Inventive Concept being claimedshould be used to interpret claim language when necessary.

First Inventive Concept—Concealed Grid Ceiling System

FIGS. 8-13 depict an exemplary ceiling system 100 according to oneembodiment of the present disclosure for forming a concealed grid. Theceiling system 100 includes a support grid 200 comprised of a pluralityof longitudinally-elongated, intersecting grid support members 202 andat least one ceiling tile 300 mounted to the support members withretaining clips 400. In one embodiment, grid support members 202 may behorizontally oriented when installed. It will be appreciated, however,that other suitable mounted orientations of support members 202 may beused such as vertical and angled or slanted (i.e. between 0 and 90degrees to horizontal). Accordingly, although support members 202 may bedescribed in one exemplary orientation herein as horizontal, theinvention is not limited to this orientation alone and otherorientations may be used.

Grid support members 202 are arranged to form an array of grid openings208 which define a grid spacing S2 that corresponds to a mountingchannel spacing S1 in the ceiling tile 300. Accordingly, spacing S2 issubstantially equal to spacing S1 to allow the grid support members 202to engage retaining clips 400 located in the mounting channels 330 ofthe ceiling tile, as further described herein. In some embodiments, thegrid support members 202 (and concomitantly mounting channels 330) maybe arranged in an orthogonal pattern wherein support members intersectat right angles to form rectilinear grid openings 208 such as squares orrectangles (in top plan view). Other shapes of grid openings 208 arepossible. The terminal ends 230 of at least some of the grid supportmembers 202 may be configured to interlock with other transverselyoriented grid support members 202 at right angles (see, e.g. FIG. 13) toform the rectilinear grid pattern in a manner well known to thoseskilled in the art without further elaboration. Any suitableinterlocking mechanism and configuration may be used.

In transverse cross section (with additional reference to FIG. 15), gridsupport members 202 may have a generally inverted T-shaped configurationwhen in an installed position either suspended from or directly attachedto an overhead ceiling support structure via an attachment mechanismsuch as without limitation fasteners, hangers, wires, cables, rods,struts, etc. Grid support members 202 may include alongitudinally-extending horizontal bottom flange 210, a bulbous topstiffening channel 220, and a vertical web 212 extending upwards fromthe flange to the stiffener. The grid support members 202 each define alongitudinal axis LA and axial direction. Web 212 may be centeredbetween opposing side ends of flange 212 in one embodiment. Bottomflange 210 defines upward facing bearing surfaces 204 configured andarranged to engage retaining clip 400. Bearing surfaces 204 are disposedon each side of web 212 and extend laterally from the web outwards tolongitudinally extending opposed lateral edges 214 of the bottom flange210. Bottom flange 210 further defines a bottom surface 206 facingdownwards towards the ceiling tile 300 and a room or space below thesupport grid. Bottom surface 206 defines a first horizontal referenceplane P1 of the overhead support grid 200 which is spaced verticallyabove a second horizontal reference plane P2 defined by the bottomsurface 304 of the ceiling tile.

Grid support members 202 may be made of metallic or non-metallicmaterial suitable to engage clips 400 and support the dead or weightload of ceiling tiles 100 without undue deflection. In some preferredbut non-limiting embodiments, support members 110 may be made of metalincluding aluminum, titanium, steel, or other.

Referring to FIGS. 5-10, ceiling tiles 300 each include a top surface302, bottom surface 304, and peripheral sides 306, 308, 310, and 312each defining a peripheral edge. The distance between opposingperipheral sides defines widths and/or lengths of the ceiling tile 300.In one embodiment, the peripheral sides may have a straight edge (see,e.g. FIG. 6) in side profile to form straight butt joints with adjacenttiles in the ceiling system 100. Other suitable edge profiles, however,such as angled, tegular, rabbeted, etc. are possible.

Top and bottom surfaces 302, 304 may be substantially planar or flat, oralternatively may include various surface features, textures, andpatterns such as perforations, wavy raised surfaces, undulating surfacecontours, linear grooves and ridges, or other. Accordingly, the top andbottom surfaces 302, 304 are not limited to any particular surfaceprofile. In one embodiment, the top surface of 302 of the ceiling tile300 may be flat which may serve as a reference surface for locating themounting channels 330 at a uniform position in each ceiling tile duringmanufacture.

Ceiling tiles 300 may have substantially uniform thickness T1 whereintop surface 302 is substantially parallel to bottom surface 304 betweenthe peripheral sides 306, 308, 310, and 312. In other possibleembodiments, top and bottom surfaces 302, 304 may be angled with respectto each other to form a reveal between adjacent ceiling tiles whereinone or more peripheral sides 306, 308, 310, or 312 project below thebottom surface 304 of an adjacent ceiling tile 300.

With continuing reference to FIGS. 5-10, ceiling tiles 300 include aplurality of longitudinally-extending recessed mounting channels 330formed through and penetrating top surface 302 so that the channels areopen in an upwards direction facing the overhead support grid 200.Channels 330 extend longitudinally across the tile and parallel to thetop and bottom surfaces 302, 304. Each channel 330 penetrates at leastone peripheral edge formed by peripheral sides 306, 308, 310, or 312 ofceiling tile 300 to allow insertion of a retaining clip 400 through aside of the ceiling tile into the channel. In one embodiment, as shownfor example in FIG. 5, the channels 330 are arranged to penetrate eachperipheral side 306, 308, 310, or 312. In this embodiment, each channel330 further penetrates two opposing peripheral sides 306, 308, 310, or312, which maximizes the possible insertion and mounting locations ofretaining clip 400 on ceiling tile 300.

It will be appreciated that in other possible configurations andarrangements of channels 330, however, that some or all of the channelsmay extend horizontally/laterally only partially across the width/lengthof the ceiling tile 300 from one peripheral side 306, 308, 310, or 312,as represented by channel 330′ shown in dashed lines in FIG. 5. Thispartial channel 330′ terminates at a dead end, which limits the maximumlateral insertion distance of the retaining clip 400 into the channel.This arrangement further limits the range of possible ceiling tilemounting locations for retaining clip 400, which may be desirable insome particular applications.

Each channel 330 includes an open top 331, an upper receptacle 332including two opposing sidewalls 333, and a lower retaining clipmounting receptacle 334. In one embodiment, sidewalls 333 may be slopedor angled with respect to a vertical centerline CV2 defined by thechannel 330. Accordingly, sidewalls 333 may each be disposed at an angleA3 to vertical centerline CV2 between 0 and 90 degrees. The angledsidewalls 333 allow the retaining clip 400 to expand laterally outwardsinto a gap G formed between the sidewalls and resiliently flexiblemounting elements such as upright wings 413 of the clip when mountingthe ceiling tile 300 to a grid support member 202, as further describedherein. The gap G may be wedge-shaped. In other possible embodiments,the sidewalls may be arranged parallel to vertical centerline CV2 (e.g.perpendicular to top surface 320) as represented by the dashed line 333′in FIG. 7 provided sufficient lateral space is created between theopposing sidewalls to allow the retaining clip 400 enough room to expandlaterally by a sufficient amount to lock the retaining clip to the gridsupport member 202.

In one embodiment, as shown in the figures, angled sidewalls 333 aredesired which forms a pair of inwardly projecting protrusions 335configured to be received at least partially in and engage a pair ofoutwardly open notches 407 of the retaining clip 400 (see, e.g. FIGS. 2,7, and 14). The protrusions 335 create a pair of opposing shoulders inchannel 330 that engage retaining clip 400. This ensures a snug fit fortightly securing the clips 400 in the channel 330 to minimize possiblerotation of the retaining clip 400 with respect to the channel 330 whenlocking the ceiling tile 300 to the support grid 200. The engagementbetween the protrusions 335 and notches 407 further creates a pivotpoint around which the angled sidewalls 333 may rotate and expandlaterally outwards when being locked to a grid support member 202.

As shown in FIG. 7, the lower mounting receptacle 334 is complementaryconfigured in cross sectional shape to the laterally widened mountingbase or flange 408 of retaining clip 400 (see also FIG. 2 of retainingclip). This securely holds the retaining clip 400 in the mountingchannel 330 of the ceiling tile 300. The mounting receptacle 334 islocated between the bottom surface 304 and top surface 302 of theceiling tile. In one arrangement, mounting receptacle 334 may be spacedvertically apart from and does not penetrate bottom surface 304 ofceiling tile 300 so that the overhead support grid 200 will becompletely concealed from view beneath the ceiling tile (see also FIG.13).

Mounting receptacle 334 defines a downward facing bearing surface 336which engages upward facing top surface 406 on retaining clip 400.Upward facing bearing surface 338 of mounting receptacle 334 engagesdownward facing bottom surface 404 of retaining clip 400. Mountingreceptacle 334 communicates with upper receptacle 332 to allow theresiliently flexible mounting wings 413 of retaining clip 400 to extendupwards through the channel 330 for engaging the support grid 200. Themounting receptacle 334 has a width W2 which is sized just slightlylarger than width W3 of mounting flange 408. This allows the mountingflange 408 to be slideably inserted and moved within channel 330 withoutexcessive looseness that might allow the ceiling tile 100 to wobble wheninstalled in the support grid 200.

A narrow throat portion 340 is formed between upper and lowerreceptacles 332, 334 by the horizontal gap created between the inwardprotrusions 335 on each sidewall 333 of the mounting channel 330, asshown in FIG. 7. The throat portion 340 has a width W6 which is smallerthan the width W3 of the retaining clip bottom mounting flange 408 (seealso FIG. 2). This prevents the retaining clip 400 from being withdrawnvertically from the ceiling tile channel 330 to ensure that the ceilingtile 300 remains secured to the overhead grid support members 202. WidthW6 of the throat portion 340 is therefore smaller than width W2 of thelower receptacle 334.

Any suitable number and arrangement of channels 330 may be provided solong as the ceiling tile 300 may be securely fastened to the overheadsupport grid 200 with retaining clips 400. In various embodiments, atleast two channels 330 arranged in intersecting or parallel relationshipto each other may be used so that the retaining clips are not allarranged in the same vertical mounting plane to avoid rotation of theceiling tile and provide secure installation. More mounting channels 330may be desired for a secure mount depending on the size and shape of theceiling tiles used. In one exemplary arrangement shown in FIG. 5,multiple intersecting channels 330 are provided. As shown each mountingchannel 330 may include one or more retaining clips 400 with at leastsome of the clips disposed near the peripheral sides 306, 308, 310, and312 of the ceiling tile proximate to where the ceiling tile will abut anadjacent tile for providing a relatively tight flush joint.

FIGS. 1-4 show a ceiling tile retaining clip 400 in greater detail.Retaining clip 400 has a generally truncated V-shaped body that definesa vertical centerline CV1 and longitudinal axis LA which generallycoincides and aligns with the longitudinal axis of a grid support member202 and axially elongated mounting channels 330 formed in the ceilingtiles 300 when the retaining clip is coupled to both the support memberand ceiling tile. Retaining clip 400 further defines a pair of axialends 442 oriented transversely to longitudinal axis LA. Retaining clip400 has an axial length L1 which may be less than the length of amounting channel 330 which may be measured along the width or lengthdimension D1 of the ceiling tile 300 (see also FIG. 5). This allows theretaining clip 400 to be mounted in a plurality of possible mountingpositions on the ceiling tile. Accordingly, mounting channel 330 has alength that is at least as long as length L1 of retaining clip 400, andpreferably longer than twice the length of L1 to provide multiplemounting locations or positions for the retaining clip.

Retaining clip 400 further includes two opposing resiliently flexibleand laterally movable upright mounting elements such as mounting wings413 extending upwards from a common mounting base such as flange 408.The mounting flange 408, being captured by the mounting channel 330 ofthe ceiling tile 300, is intended to remain relatively stationary inposition during the process of mounting the ceiling tile to the supportgrid 200 whereas the mounting wings 413 are elastically deformable tolock the ceiling tile to the support grid, as further described herein.

The body of the retaining clip may be formed as a single unitarystructure in which the mounting wings 413 and mounting flange 408 areall integral portions of the unitary body. In other possibleembodiments, the mounting wings 413 may be separate elements coupled tomounting flange 408 in any suitable manner such as welding, solder,fasteners, interlocked structures, etc.

Referring generally now to FIGS. 1-4, 7, 13, and 14, the mounting wings413 are spaced laterally apart to define a widened entrance or topopening 422 having a width W4 (measured between top edges 403) that issized to receive the bottom flange 210 of a grid support member 202 wheninserted vertically downwards into the retaining clip. Accordingly,width W4 is larger than the lateral width W5 of the bottom mountingflange 210 of the grid support member 202. Each mounting wing 413includes an upper section 412 defining an upper free terminal edge 403,a middle section 411, and a lower end 410 which conjoins bottom mountingflange 408. In some embodiments, upper section 412 of each mounting wing413 may be flared outwards about a bend line 409 at an angle A4 to themiddle section 411. Angle A4 may be between 0 and 90 degrees, andpreferably between 0 and 45 degrees in various embodiments. Eachmounting wing 413 further defines a pair of inner bearing surfaces 416which face inwards towards each other and vertical centerline CV1defined by the retaining clip 400. The bearing surfaces 416 areconfigured and arranged to slideably engage bottom flange 210 of a gridsupport member 202 during the ceiling tile mounting process, as furtherdescribed herein.

Mounting wings 413 may be slanted and angled outwards away from verticalcenterline CV1 and diverge by a progressively increasing horizontaldistance from centerline CV1 in moving vertically upward away from thebottom mounting flange 408, as shown. In one embodiment, each mountingwing 413 may be disposed at an angle A1 from vertical centerline CV1between 0 and 90 degrees, and more preferably between 0 and 45 degrees.The angled wings 413 define an interior cavity 420 therebetweenconfigured and dimensioned to receive bottom flange 210 at leastpartially into the cavity (see, e.g. FIG. 13). In one embodiment, cavity420 may have a frusto-conical shape in transverse cross section.

Bottom mounting flange 408 of retaining clip 400 defines an opposingpair of laterally outward extending engagement protrusions 440configured to engage lateral end portions of lower mounting receptacle334 in the ceiling tile 100. Mounting flange 408 includes an outerbottom surface 404, opposing outer top surface 406, opposing inner topsurface 441, and a pair of opposing longitudinally-extending lateralends 405 oriented parallel to longitudinal axis LA. The distance betweenthe ends 405 defines a mounting flange width W3. Each mounting wing 413is disposed at an angle A5 to the top surface 406 of the mounting flange408. In some embodiments, angle A5 may be between 0 and 90 degrees whichcreates the angled or sloped inner bearing surfaces 416 inside theretaining clip opposite outer surfaces 401 of the mounting wings 413.The inner bearing surfaces 416 may be substantially parallel to outersurfaces 401 creating a substantially uniform thickness T2 for eachmounting wing 413 (see also FIG. 2).

In one embodiment, bottom mounting flange 408 of retaining clip 400 mayhave an at least partially open interior space defined between thevertically spaced apart top and bottom surfaces 406, 404 of the flange.The mounting flange 408 may form a generally V-shaped shoulder or corner424 (which may be slightly rounded) forming a laterally narrowed throatportion 450 of the retaining clip 400 and outwardly open notches 407configured for engaging mounting channel 330, as described herein. Theinwardly projecting corners 424 are resiliently flexible and verticallymovable to a degree upon applying a generally downward force against thetop edges 403 of the mounting wings 413. Accordingly, top surface 406 ofmounting flange 408 is in turn resiliently deformable to a degree withrespect to the bottom surface 404 due to the open interior space formedbetween the surfaces. This may assist with sliding and then maintainingthe retaining clips 400 in a desired mounting position within thelongitudinally extending channels 330 formed in the ceiling tiles 300.For example, a clip 400 may be inserted into a channel 330 through aperipheral side 306, 308, 310, or 312. The installer may then pressdownwards with a force against the mounting wings 413 which temporarilyand resiliently deforms the corners 424, thereby displacing themslightly downwards to relieve some of the frictional pressure betweenthe adjacent top surface 406 of the mounting flange 408 and the downwardfacing bearing surface 336 in the lower receptacle of the ceiling tilechannel (reference FIG. 7). This allows the clip 400 to slide moreeasily within the channel 330. When a desired position of the clip 400is reached, the installer releases the mounting wings 413 therebyremoving the downward force. The top surface of retaining clip 400springs back upwards and increases the frictional force against thebearing surface 336 to help frictionally retaining the clip in positionwith channel 330 until the ceiling tile 300 is mounted to the overheadsupport grid 200.

It will be appreciated that in other possible embodiments, the bottommounting flange 408 of retaining clip 400 may be solid without aninterior space and vertical deformability between the top and bottomsurfaces 406, 404.

Referring to FIGS. 1-4, retaining clip 400 further includes at least oneopposing pair of resiliently movable locking tabs 402 which are eachconfigured to engage grid support member 202 for locking the ceilingtile 100 to the support grid 200. Locking tabs 402 may each be hingedlyconnected to a mounting wing 413 at a top hinged end 402 a and have abottom free end 402 b which engages upward facing bearing surface 204 onthe bottom flange 210 of the grid support member 202, as further shownin FIG. 13. In one embodiment, the free ends 402 b of tabs 402 arearranged to engage the opposing longitudinally extending lateral edges214 of the bottom flange 210.

As best shown in FIG. 2, locking tabs 402 project inwards from eachmounting wing 413 of retaining clip 400 and are disposed at an angle A2to the wings. In one non-limiting embodiment, angle A2 may be between 0and 45 degrees. The tabs 402 are movable laterally outward by engagementwith the bottom flange 210 of the grid support member 202 when insertedinto the retaining clip 400. The grid support member 202 creates alaterally outward force against the locking tabs 402 to temporarilydeflect and spread the tabs apart. The locking tabs 402 elasticallyreturn inwards towards an undeflected position upon disengagement fromthe bottom flange 210 of the grid support member 202. The tabs 402 maybe rigidly structured with respect to the mounting wings 413 (e.g. bymaking the vertical length of the tabs relatively short) so that thegrid support member 202 deflects both the tabs and mounting wing uponcontact. In other embodiments, the tabs 402 may be movable with respectto the mounting wings 413 to a degree such that the grid support member202 deflects either the tabs alone upon contact or both the tabs andmounting wings. Any of the foregoing constructions are satisfactory solong as the locking tabs 402 are deflected and spread apart by the gridsupport member 202.

The locking tabs 402 are disposed between the top edges 403 and bottommounting flange 408 of the retaining clip 400 at a position that islocated between the top and bottom surfaces 302, 304 of the ceiling tilewhen the retaining clip is mounted therein (see, e.g. FIG. 13). Thisprovided a stable ceiling tile mount and minimizes the total combinedheight of the ceiling tile and grid support member combination forcompact installations. In one embodiment, the locking tabs may belocated more proximate to the bottom mounting flange 408 of retainingclip 400 than the top edges 403 at a position adjacent to throat portion450 where the width of the retaining clip cavity 420 is less than thewidth W5 of the grid support member bottom flange 210 to trap the flangebeneath the locking tabs (see also FIGS. 2, 7, and 13-15).

The locking tabs 402 may be formed as an integral unitary structuralpart of the mounting wings 413 by creating a three-sided rectilinear cutin the wing and bending the tabs inwards away from the wings towardsvertical centerline CV1. This embodiment formed a cutout window 425 inthe mounting wings 413 below the hinged end 402 a of each locking tab402. Each locking tab 402 is laterally moveable into and out of itsrespective window 425.

In other possible embodiments contemplated, locking tabs 402 may beformed as separate elements which are attached to mounting wings 413 byany suitable means to form a hinge such as with fasteners, soldering,welding, adhesives, or other. In one preferred embodiment, the lockingtabs 402 are integrally formed from a part of mounting wings 413 in themanner described above for simplicity of manufacture andcost-effectiveness. Any suitable number of locking tabs 402 may beprovided. Each mounting wing 413 preferably includes at least onelocking tab 402.

When retaining clip 400 is mounted in a mounting channel 330 of theceiling tile 300, the upper portion and top edges 403 of mounting wings413 extend vertically above the top surface 302 of the ceiling tile asshown for example in FIGS. 7, 10, and 13. This positions the mountingwings 413 to cleanly receive and engage a grid support member 202 beinginserted through the top opening 422 of the retaining clip.

Retaining clips 400 may be made of any suitable resiliently deformablemetallic or non-metallic material having an elastic memory which allowsmounting wings 413 and locking tabs 402 to be laterally deflected bygrid support members 202 and then return towards the originalundeflected position. In one preferred embodiment, retaining clips 400may be made from spring steel or other resiliently deformable metal. Inother possible embodiments, a suitably strong and resilient plasticmaterial may be used. The retaining clips 400 may be fabricated by anysuitable method(s) used in the art such as without limitation stamping,bending, extrusion, cutting, and others depending on the shape andmaterial of construction intended for the clips.

A method or process for mounting a ceiling tile to an overhead supportgrid of a ceiling system will now be described. In one embodiment, theceiling system is a concealed grid ceiling system 100. As furtherdescribe below, the grid support member 202 is vertically movable froman entrance position to a locked position in the retaining clip whereinthe grid support member is locking engaged with the retaining clip.

The method begins with first providing the ceiling system components, asshown for example in FIG. 8. This includes a support grid comprised of aplurality of grid support members 202 which have been preassembled andalready mounted from or to an overhead support structure in theconfiguration shown in one exemplary embodiment, a ceiling tile 300, anda plurality of retaining clips 400.

Referring generally to FIGS. 5-13, the method continues by nextinstalling the retaining clips 400 in the mounting channels 330 in theceiling tile 300. The clips 400 are each laterally and slideablyinserted through open ends of the mounting channels 330 formed throughperipheral sides 306, 308, 310, and/or 312 of the ceiling tile 300.After initial insertion of a clip 400 into a channel 330, the installermay optionally press downwards against the mounting wings 413 to relievethe frictional engagement between the upward facing top surfaces 406 ofthe clip mounting flange 208 and downward facing surfaces in the lowermounting receptacle 334 of the channels 330, in the manner alreadydescribed herein. The retaining clips 400 may be slid along the lengthof the channels between a continuum of possible axial mounting positionsin the channels between the peripheral sides of the ceiling tile 300.When the desired mounting position is reached, the retaining clip 400may be released by the installer. The clips 400 are maintained inposition by frictional engagement with the mounting channels 330. Theclips 400 are positioned and ready for mounting to the support grid 200.The upright mounting wings 413 of the retaining clips 400 are in aninitial undeflected position.

In one embodiment, the retaining clips 400 are preferably located sothat a clip is positioned proximate to the peripheral sides of theceiling tile in each of the mounting channels 330 (see, e.g. FIGS. 5, 9,and 10). In some embodiments, the retaining clips 400 may be spacedinwards in the channels 330 away from the peripheral sides, as shown.This retaining clip 400 position ensures that the peripheral sideregions of the ceiling tile are securely mounted to the overhead supportgrid 200 to form relatively tight joints with and substantially flushbottom surfaces between adjacent tiles for aesthetic reasons. Additionalintermediate retaining clips 400 may be provided between theperipherally-located clips for added support, as needed depending on thesize and weight of the ceiling tile 300.

With the retaining clips 400 now installed in the foregoing mountedpositions in mounting channels 330, the ceiling tile 300 is raisedvertically upwards towards the support grid 200 so that the ceiling tileis proximate to the grid (see, e.g. FIG. 9). The horizontal position andorientation of the ceiling tile 300 may be adjusted so that theretaining clips 400 are each vertically aligned with a correspondinggrid support member 202. Since the installer is located below theceiling tile 300 during installation, the support members 202 above thetile cannot generally be viewed directly. However, because the gridsupport members 202 each form axially aligned runners and cross-pieceswith remaining exposed support members, the installer can approximatethe proper horizontal position of the ceiling tile as needed.

The installer next raises the ceiling tile 100 vertically upwardsagainst the overhead support grid 200, preferably creating light contactinitially. The horizontal position and orientation of the ceiling tile300 may be adjusted so that the bottom flanges 210 of the grid supportmembers 202 are horizontally and vertically centered over the topopenings 422 of the retaining clips 400 so that the vertical centerlinesCV1 and CV2 of the retaining clips and ceiling tile mounting channels330 are substantially aligned. The widened top opening 422 of theretaining clips 400 facilitates this positioning. Because the top edges403 of the retaining clips 400 are raised above the top surface 302 ofthe ceiling tile, the installer can generally determine by feel that thebottom flanges 210 of the grid support members 202 are properly alignedwith the top openings 422 of the retaining clips 400. At this point inthe installation process, the retaining clips 400 are not lockinglyengaged with the grid support members 202.

With the retaining clips 400 now properly aligned with the grid supportmembers 202, the ceiling tile 300 is further raised vertically upwardstowards the support grid 200. The bottom flange 210 of each grid supportmember 202 travels downwards in cavity 420 from the top opening 422 ofthe retaining clip 400 towards the bottom mounting flange 408 of theretaining clip. As the cavity 420 of the retaining clip 400 graduallynarrows towards the bottom (see, e.g. FIG. 7 entrance width W4 to throatportion 450 width W1), the longitudinally extending lateral edges 214 ofthe bottom flange 210 moves downwards and may slidingly engage one orboth inner bearing surfaces 416 of the retaining clip 400 depending onthe width W5 of the grid support member mounting flange 210 and of thecavity at different portions. Accordingly, in some embodiments, theopposed lateral edges 214 of the bottom flange 210 may mutually engageportions of the inner bearing surfaces 416 on each mounting wing 413above the locking tabs 402, which would deflect the elastic mountingwings 413 laterally outwards in opposing directions and narrows thewidth of gap G formed on each side of the retaining clip (referenceFIGS. 7 and 13). In other embodiments, the opposed lateral edges 214 ofthe bottom flange 210 may not engage portions of the inner bearingsurfaces 416 on each mounting wing 413 above the locking tabs 402, inwhich case no deflection of the mounting wings would occur.

Eventually, lateral edges 214 of the bottom flange 210 on the gridsupport member 202 approach and slidingly engage the locking tabs 402 ofthe retaining clip 400. This gradually deflects the tabs 402 laterallyoutwards farther and farther as the support member 202 progressesdownward in the retaining clip. In some embodiments, the locking tabs413 may be somewhat rigidly structured in relation to the mounting wings413 so that the grid support member 202 deflects and spreads themounting wings outward with the locking tabs. In other possibleembodiments, the locking tabs 402 alone may be deflected towards themounting wings 413 or both the locking tabs and mounting wings may bespread apart by the mounting flange 210 of the grid support member 202.

In any of the foregoing deflection scenarios, the locking tabs 402 arespread apart by sufficient horizontal distance to allow the opposedlateral edges 214 of the bottom flange 210 on the grid support member202 to pass by the locking tabs. Once the lateral edges 214 reach aposition below free end 402 b of the retaining clip 400 (see also FIGS.1-4), the locking tabs 402 snap back inwards engaging the top surface204 of the bottom flange 210 near the lateral edges 214 of grid supportmember 202, as shown in FIGS. 13 and 14. The mounting wings 413 and/orlocking tabs 402 alone may each return inwards to a substantiallyundeflected position. The ceiling tile 300 is now snap-fit and lockinglyengaged with the overhead support grid 200 in a fully mounted position.The locking tabs 402 of the retaining clip 400 are substantially alignedin the same horizontal plane P1 as the bottom mounting flanges 210 ofthe grid support members 202 when the ceiling tile 300 is fully mountedto the support grid 200. As best shown in FIG. 14, the lateral edges 214of the grid support member 202 are trapped between the free ends 402 bof locking tabs 402 and inner bearing surface 416 in the narrowed throatportion 450 of the retaining clip 400 because the throat portion has asmaller width W1 than width W5 of the grid support member mountingflange 210. The grid support member 202 cannot be vertically withdrawnfrom the retaining clip 400 without first forcing the locking tabs 402back outwards to disengage the tabs from the bottom mounting flange 210,and then raising the grid support member 202 upwards by simultaneouslylowering the ceiling tile 300. When the ceiling tile is mounted to thesupport grid 200, the locking tabs 402 of the retaining clip 400 aregenerally accessible from only above the ceiling tile 300.

It should be noted that the foregoing ceiling tile snap-fit mountingmechanism creates an audible “click” to confirm to the installer thatthe ceiling tile 300 has been fully and properly mounted.Advantageously, this assists signals installers who cannot directly seethe engagement between the retaining clips 400 and the grid supportmembers 202.

The foregoing ceiling tile installation process may be repeated asnecessary to add additional ceiling tiles 300 to the support grid 200.

It will be appreciated that the ceiling tile 300 mounting systemdescribed herein advantageously does not limit the shape of ceilingtiles that may be used. The mounting is controlled by thepattern/arrangement and lateral spacing of the overhead grid supportmembers 202 and their mating mounting channels 330 formed in the topsurface 302 of the ceiling tile 100 which hold the retaining clips 400.The arrangement of the grid support members 202 and mounting channels330 is therefore independent of the shape of the ceiling tile used.Accordingly, ceiling tiles 300 may be used having different shapes thanthe openings 208 formed by the grid support members 202 and the layoutof the mounting channels 330.

Although a square rectilinear ceiling tile is shown herein fordescribing one possible non-limiting embodiment, the invention is notlimited to such rectilinear shapes (e.g. square, rectangular) alone.Other polygonal shapes (e.g. diamond, triangular, hexagon, etc.) andcombinations of shapes may be used for ceiling tiles and mounted to anoverhead support grid in accordance with the ceiling tile mountingsystem disclosed herein.

Second Inventive Concept—Ceiling System with Concealed Support Grid

A ceiling system includes a grid support member, and first and secondceiling panels abutted at a joint. In the factory-supplied condition,each panel has a facing sheet already adhesively bonded to a centralregion of the panel. Perimeter portions of the facing are left un-bondedto an annular peripheral region of the surface surrounding the centralregion. This allows seams to be made in the field. The facing sheetcomprises a cantilevered flap extending beyond a peripheral edge of thepanel. During field installation, the flap of a first panel extendsacross the joint overlapping the second panel's un-bonded facing sheetin the peripheral region. The double thickness of facings is cut to forma seam laterally offset from the joint, which is concealed. A fieldapplied or activated adhesive bonds the facing to the peripheral regionsof each panel. A related installation method is disclosed.

FIG. 16 depicts an exemplary embodiment of a ceiling system 1100according to the present disclosure. The ceiling system 1100 includes anoverhead support grid 1200 including a plurality of overheadlongitudinal grid support members 1202 and ceiling panels 1300 supportedby the grid support members. The grid support members 1202 are mountablein a suspended manner from an overhead building support structure. Thesystem may include at least two panels 1300 having abutted peripheraledges which form a joint 1303 therebetween. In one embodiment, the jointmay be formed beneath the grid support member 1202 as seen in FIG. 31.The panels 1300 may be directly mounted to the grid support members 1202in one arrangement by any suitable means, for example without limitationthreaded fasteners 1305 which are driven through the panel and gridsupport member as shown. In embodiments as shown in FIG. 32, aninterlock fit between the ceiling panels 1300 allows a first panel to besecured to the grid support member 1202 while the other panel issupported by the peripheral edge of the first panel. Other suitablepanel mounting arrangements and methods are possible to hang the panelsand form the joint.

Referring additionally to FIGS. 16 and 22, grid support members 1202 areelongated in shape having a length greater than their width (e.g. atleast twice), and in various embodiments lengths substantially greaterthan their widths (e.g. 3 times or more). The grid support members 1202may form “runners” or “rails” and are laterally spaced apart andoriented parallel to each other to position a ceiling panel 1300therebetween. In some embodiments, the longitudinal grid support members1202 may be maintained in a substantially parallel spaced apartrelationship to each other by lateral grid support members (not shown)attached between adjacent (but spaced apart) grid support members 1202at appropriate intervals using any suitable permanent or detachablemanner of coupling.

In one embodiment, grid support members 1202 may be horizontallyoriented when installed. It will be appreciated, however, that othersuitable mounted orientations of grid support members 1202 such asangled or sloped (i.e. between 0 and 90 degrees to horizontal) may beused. Accordingly, although support members 1202 may be described in oneexemplary orientation herein as horizontal, the invention is not limitedto this orientation alone and other orientations may be used.

Grid support members 1202 may be T-shaped (e.g. T-rails) in transversecross section. The grid support members have an inverted T-shapedconfiguration when in an installed position suspended from an overheadbuilding ceiling support structure. The grid support members 1202 may besuspended from the building ceiling support structure via an appropriatehanger mechanism, such as for example without limitation fasteners,hangers, wires, cables, rods, struts, etc.

Grid support members 1202 in one non-limiting configuration may eachinclude a longitudinally-extending horizontal bottom flange 1210, anenlarged top stiffening channel 1220, and a vertical web 1212 extendingupwards from the flange to the stiffening channel. In some embodiments,the top stiffening channel 1220 may be omitted. The grid support members1202 each define a respective longitudinal axis LA and axial directions.Bottom flange 1210 has opposing portions which extend laterally outwardsfrom web 1212 and terminate in opposed longitudinally extending paralleledges 1214. Web 1212 may be centered between the edges 1214 andvertically aligned with the centerline 1CL1 of the grid support memberin one non-limiting embodiment. In other embodiments, the web 1212 maybe laterally offset from centerline 1CL1. Bottom flange 1210 furtherdefines a bottom surface 1206 facing downwards away from the flange andtowards a room or space below the support grid 1200. Bottom surface 1206defines a horizontal ceiling reference plane or “grid face” for theoverhead support grid 1200. Flange 1210 further defines a top surface1216 opposite the bottom surface for attaching and supporting theceiling panel 1300 in some embodiments.

Grid support members 1202 may be made of any suitable metallic ornon-metallic materials structured to support the dead weight or load ofceiling panels 1300 without undue deflection. In some non-limitingembodiments, the grid support members may be made of metal includingaluminum, titanium, steel, or other. In one embodiment, the grid supportmembers 1202 may be a standard heavy duty 15/16 inch aluminum T-rail.Other shapes of grid support member structures that may be used includesolid or hollow square or rectangular structural cross-sections andothers.

Referring now FIGS. 16-21, ceiling panel 1300 may have a generallyflattened rectilinear acoustic panel body 1301 with a substantiallygreater horizontal width and length than vertical thickness as shown.Ceiling panel 1300 includes a top surface 1302, bottom surface 1304, andperipheral edges 1306 extending therebetween along four sides of thepanel. In various embodiments, the peripheral edges may have variousedge profiles including straight edges, angled or sloped edges, steppedtegular edges, shiplap edges, tongue and groove edges, or hybrid edgesas shown in FIG. 32 combining a shiplap and tongue and groove features.Other edge profile configurations are possible. Top and bottom surfaces1302, 1304 may be generally planar or flat and arranged substantiallyparallel to each other in one non-limiting embodiment. In otherarrangements, the top and bottom surfaces may be angled with respect toeach other.

Ceiling panels 1300 have acoustic panel bodies 1301 may be constructedof any suitable sound-absorbing material including without limitationmineral fiber board, fiberglass, jute fiber, wood, composites, or other.In addition, the ceiling panels 1300 may have any suitable dimensionsand shapes (in top plan view) including without limitation square orrectangular with unequal length sides.

The bottom surface 1304 of the ceiling panel 1300 defines a centralregion 1310 and annular peripheral region 1311 which surrounds thecentral region. The peripheral region 1311 extends between the centralregion and each of the peripheral edges 1306 of the panel forming aframe around the central region, as best shown in FIGS. 18 and 19. Thecentral region 1310 and peripheral region may each have a rectilinearshape in bottom plan view for reasons which will become apparent. Inone, peripheral region 1311 has a width 1W1 which is smaller than thewidth 1W2 and length 1L of the central region 1310. The width 1W2provides a corresponding distance between the peripheral edges 1306 ofthe ceiling panel 1300 and the central region 1310 for fitting andcutting adjoining facing sheets during the field installation.

Ceiling panel 1300 further includes a factory-mounted bottom facingsheet 1330 which is attached to the bottom surface 1304 of panel body1301 during fabrication of the panel at the factory prior to shipping.This ensures that the facing sheet has the proper orientation anddimensions desired with respect to the panel body 1301. In oneembodiment, the facing sheet 1330 covers at least the entire bottomsurface 1304 of the ceiling panel 1300. Facing sheet 1330 has a thinflat structure and may be rectilinear in shape (bottom plan view)including a top surface 1331, opposing bottom surface 1332, andplurality of perimeter edges 1333 extending therebetween around thesheet. The perimeter edges 1333 are straight in one embodiment such thateach edge is oriented perpendicular to the two adjoining edges whichmeet at the corners of the sheet. Preferably, the facing sheet is formedof a single monolithic unitary sheet of material rather than being anamalgamation of separate sheets seams together. In other less preferredbut suitable embodiments, however, the facing sheet 1330 may be formedof two or more sheets of material seamed together.

In one non-limiting embodiment, facing sheet 1330 may be adhesivelybonded to only the central region 1310 of the bottom surface 1304 ofceiling panel 1300 at the factory with a suitable factory applied thinadhesive film or layer 1340. Industrial adhesives which may be usedinclude Swift® tak water-based adhesives from H.B. Fuller Company andothers. The annular perimeter portions 1334 of the facing sheet 1330(which correspond in position to at least the underlying annularperipheral portion 1311 of the panel bottom surface 1304) are notadhesively bonded to the peripheral portion to allow for field fitting,cutting, and seaming of the facing during installation of the ceilingsystem 1100, as further described herein.

As demonstrated by FIG. 6, the acoustic panel body 1301 may have a panelcenter point 1308, which is a point on the bottom surface 1304 of theacoustic panel body 1301 and equidistant between opposing peripheraledges 1306 of the acoustic panel body 1301. The facing sheet 1330 mayhave a sheet center point 1338, which is a point on the bottom surface1334 of the facing sheet 1330 that is equidistant between opposingperipheral edges 1333 of the facing sheet 1330. The panel center point1308 and the sheet center point 1338 may be offset from one another by adistant that is parallel to the bottom surface 1304 of the acousticpanel body 1301.

In some embodiments, the bottom facing sheet 1330 may be in the form ofa scrim comprised of laminated non-woven glass fibers in a resin matrix.This type construction is suitable for high end acoustical panels toimpart a smooth visual appearance, durability, and dimensionalstability. Other suitable scrim materials may be used for the bottomfacing sheet 1330 and are available from suppliers such as OwensCorning, Lydall, Ahlstrom, and Johns Manville. Such materials mayinclude films, sheets, woven materials and open cell foamed materials.

Referring to FIGS. 16-27, the perimeter portion 1334 of bottom facingsheet 1330 in one embodiment forms at least one cantilevered extensionor flap 1335 that projects laterally outwards in a horizontal directionbeyond at least one peripheral edge 1306 of the ceiling panel 1300 by adistance 1D1 (identified in FIG. 17). Accordingly, bottom facing sheet1330 has a larger horizontal length or width in at least one directionmeasured between opposite perimeter edges 1333 than the correspondinglength or width of the ceiling panel 1300 in that same directionmeasured between opposite peripheral edges 1306. In one embodiment, theflap 1335 is continuous and extends in uninterrupted manner along theentire peripheral edge 1306 of the ceiling panel from corner to corneras shown. The unsupported flap 1335 allows the facing sheet 1330 toextend across and over the joint 1303 beneath the grid support member1202 to an adjoining ceiling panel 1300 and at least partially acrossthe peripheral region 1311 of that adjoining panel, thereby concealingthe panel joint.

In some embodiments, two laterally extending cantilevered flaps 1335 areformed from bottom facing sheet 1330 on adjacent peripheral edges 1306of the ceiling panel 1300 which meet at a corner, as shown in theillustrated embodiment. Accordingly, a long side and an adjoining shortside of the panel each include a facing flap 1335. The perimeter portion1334 of the facing sheet on the remaining panel peripheral edges 1306opposite each of the flaps does not extend beyond their respectiveperipheral edge, and in some embodiments may terminate at a point beforethe peripheral edge somewhere within the outer peripheral region 1311 onthe ceiling panel bottom surface 1304. The peripheral region 1311 formsa cutting zone for cutting and seaming the facing sheets from twoadjoining ceiling panels. When the ceiling panels 1300 are installed inthe ceiling system 1100 as shown in FIGS. 28-31 to be further describedherein, this arrangement of flaps on two sides alone is sufficient tocover the ceiling panel joints without leaving any portions of the panelbottom surfaces exposed, while minimizing the amount of excess facingwhich needs to be removed by the installer. However, in otherembodiments contemplated, the facing sheet 1330 may be configured toform unsupported cantilevered flaps 1335 along all peripheral edges 1306of the panels 1300.

A method for installing a ceiling system and seaming factory-installedfacing during field installation of the system according to the presentdisclosure will now be described. FIGS. 23-27 illustrate sequentialsteps in one non-limiting embodiment of the process; however, it will beappreciated that variations are possible. The grid support member 1202from which either one or both of the ceiling panels are supported(depending on the edge profile design of the panels selected) is shownonly in FIGS. 23 and 24 for clarity in showing the remaining steps inthe facing seaming process.

Referring to FIG. 23, first and second ceiling panels 1300 to be joinedare provided and transported to the field installation site. Each panelincludes a facing sheet 1333 which is pre-mounted to the bottom surfaces1304 in the factory with the factory-applied adhesive layer 1340 asalready described herein. The facing sheet is only adhesively bonded tothe bottom surface central region 1310 of each panel, and not theperipheral regions 1311. The panels 1300 are positioned beneath gridsupport member 1202, which is mounted to an overhead ceiling supportstructure of the building. The first ceiling panel 1300 may be mountedto the grid support member via fasteners 1305 or another suitablemounting mechanism by pulling back the facing sheet to access bottomsurface of ceiling panels for installing mounting hardware. Theperipheral edges 1306 of the panels are then abutted (or interlocked inthe embodiment of FIG. 32) by laterally engaging the edge of the secondceiling panel with the first, thereby forming field joint 1303 betweenthe panels as shown in FIG. 24. Once positioned, the second ceilingpanel 1300 may then be mounted to the grid support member 1202 and/orfirst ceiling panel for support.

As seen in FIG. 24, the adjoining ceiling panels 1300 are oriented andmounted so that peripheral edge 1306 of one first panel has acantilevered facing flap 1335 adjacent the joint (e.g. left panel inthis figure) and the other second panel (right panel) has a mating edgethat does not have a flap (i.e. facing sheet 1330 not extending beyondthe peripheral edge of the second panel). The flap 1335 extends acrossand under the joint 1303 and overlaps the un-bonded or un-adheredperimeter portion 1334 of the facing sheet 1330 on the second ceilingpanel 1300, thereby forming a double thickness of facing material in theperipheral region 1311 of the second panel's bottom surface 1304.

The next step involves establishing a cut line 1342 in the doublethickness of facings 1333 which is laterally offset from the panel joint1303 and lies somewhere within the peripheral region 1311 of the second(right) ceiling panel 1300. As shown in FIG. 10, a knife blade or othersharp edged cutting tool 1345 is run linearly along the cut line 1342(i.e. into the sheet shown in the figure) to cut through the overlappingdouble facings 1330 of the first ceiling panel 1300 (i.e. flap 1335) andsecond ceiling panel. The excess severed pieces or end segments 1343,1344 of the facing sheets 1330 (which would be strips of facing inactuality) are then removed and discarded, thereby leaving an abutmentseam 1343 between the adjoining facings 1330 which is located in theperipheral region 1311 of the second ceiling panel (right) as shown inFIG. 26. The ceiling panel joint 1303 is concealed beneath the facingsheets; specifically the facing sheet 1330 of the first ceiling panel onthe right. The seam 1343 is laterally offset from the ceiling paneljoint.

For attaching and bonding the perimeter portions 1334 of the facingsheets 1330 to bottom surfaces 1304 of both the first and second ceilingpanels of each panel, a suitable adhesive layer 1341 is then appliedand/or activated in the field to the peripheral regions 1311 of eachpanel. The facing sheets are contacted with the field adhesive layer tocomplete the facing bonding and seaming process, as shown in FIG. 27.The field applied or activated adhesive layer 1341 covers the portionsof the ceiling panels in the joint area between the central regions 1310which were previously already adhered to the panels at the factory. Insome embodiments, an inactivated adhesive layer may be pre-applied tothe peripheral regions of the ceiling panel bottom surfaces 1304 in thefactory prior to shipment, which is then activated in the field by theinstaller for bonding the facing to the panels. Either approach isacceptable.

Numerous types of field applied or activated adhesive layers 1341 may beused, such as for examples without limitation heat or ultravioletactivated adhesives, pressure sensitive adhesives, spray adhesives, andhot melt adhesives (e.g. heat activated or applied hot). Yet other fieldadhesives and bonding methods that may be used also includesdouble-sided adhesive strips or tape. The field applied or activatedadhesive layer 1341 may be a permanent type of adhesive, oralternatively a semi-permanent and releasable adhesive to allow thefacing sheet to lifted at the seams 1343 if necessary for adjustments oraccess to the ceiling panel and mounting hardware above the facing.

In one embodiment, the type of factory-applied adhesive layer 1340 usedto bond the facing sheets 1330 to the central regions 1311 of theceiling panel bottom surfaces 1304 may be different than the type offield adhesive layer 1341 used. Certain adhesives are better suited forinstallation in a factory under precisely controlled fabrication andadhesive curing conditions rather than in the field requiring quicklycuring or activated adhesives to enhance ceiling system installationproductivity.

It is important to note that the thicknesses of the adhesive layers 1340and 1341 have been intentionally exaggerated for illustration purposesonly to clearly show the boundaries between the factory applied adhesivein the central region 1310 of the ceiling panels 1300 and the fieldapplied or activated adhesives in the surrounding annular peripheralregions 1311. In actuality, the thickness of the adhesive layers is deminimis such that the facing sheet 1330 lies substantially in the samehorizontal plane as the bottom surface 1206 of the grid support memberbottom flange 1210. Accordingly, there would be no clearly discerniblegaps between the facing sheet and bottom surface of the ceiling panels.The adhesive layers 1340 and 1341 should therefore not be construed orinterpreted as actual physical structures such as spacers or othermembers sometimes used in ceiling panel construction to accommodateinsertion of a portion of the bottom flange into the gap for mountingthe panels.

It will be appreciated that numerous variations in the foregoing ceilingpanel installation and facing seaming process and sequence are possible.

Additional ceiling panels 1300 may be installed in a similar manner, asshown schematically in the bottom plan views of FIGS. 28-31. Thesefigures depict one embodiment of sequential steps for mounting andassembling an array of panels. The ceiling panel peripheral edges 1306are shown in dashed lines beneath the facing sheets 1330. It bearsnoting that the perimeter edges 1333 of the cantilevered facing flaps1335 are each positioned in a peripheral region 1311 of the adjoiningceiling panel across the panel joint 1303 which form facing seams 1343lying in the same regions.

The foregoing facing seaming process may similarly used and followed forinterlocking panels as shown in FIG. 32 which include hybrid panel edgeprofiles which combine including shiplap and tongue and groove feature.One abutting ceiling panel 1300 includes an upper shiplap profile orfeature 1340 adjacent top surface 1302 and the mating panel includes alower shiplap profile or feature 1350 offset and spaced verticallyapart/downward from the top surface of each panel 1300. The panel 1300with the upper shiplap feature 1340 (right panel) includes a laterallyopen groove 1370 in the panel peripheral edge which receives a laterallyoutward projecting cantilevered tongue 1360 formed on the mating edge ofthe panel having the lower shiplap feature 1350 as shown. Joint 1303between the panels 1300 has a compound rectilinear shape.

The peripheral edges 1333 including a lower shiplap feature 1350 mayfurther include a male shiplap feature comprising a laterally outwardprojecting cantilevered tongue 1360 configured for insertion into amating female shiplap feature comprising a laterally open groove 1370formed in an adjoining ceiling panel peripheral edge 1333 (see, e.g.FIGS. 23 and 9).

Accordingly, the type of panel edge details used is not limiting of theinvention or restrictive.

Third Inventive Concept—Faced Ceiling System

A ceiling system in one embodiment conceals joints between adjoiningceiling panels to provide a monolithic ceiling appearance. The systemincludes the support structure and ceiling panels each having a topsurface, bottom surface, and peripheral edges. In one embodiment, theperipheral edges of the panels may have a hybrid edge detail including afirst edge profile and a second edge profile different than the first. Afacing material, bonded to the bottom surfaces of ceiling panels aftersecurement to the support structure, has a continuous uninterruptedextent to cover and conceal multiple panels and joints. The facing maybe adhesively bonded to the panels.

The present ceiling system 2100 will now be described for conveniencewithout limitation to a suspended type ceiling system having a grid-typeceiling panel support system which is hung from an overhead buildingstructure. However, the ceiling system is not limited in its scope orapplicability to such grid systems. Accordingly, the support grid may bedirectly surface mounted to the building structure in certainembodiments. Alternatively, the ceiling panels themselves may bedirectly surface mounted to the building structure or framing members(e.g. wood or metal joists, studs, or other elements). Therefore, thepresent invention is explicitly not restricted for use with suspendedtype ceiling systems alone.

Referring initially now to FIGS. 33 and 34, the ceiling system 2100generally includes an overhead grid support system 2200 forming aceiling support structure for mounting a plurality of ceiling tiles orpanels. In one embodiment, the grid support system 2200 may beconfigured for mounting in a suspended manner from an overhead buildingstructure via appropriate hanger elements 2203, such as for examplewithout limitation fasteners, hangers, wires, cables, rods, struts, etc.Grid support system 2200 defines a support grid 2209 comprising aplurality intersecting longitudinal grid support members 2202 (e.g. mainbeams) and lateral grid support members 2204 (e.g. cross tees). Thelongitudinal grid support members 2202 may be referred to as main beamsbecause these grid members in some embodiments alone may be hung byhanger elements 2203 from an overhead building structure, therebyproviding support for the entire grid. The lateral grid support members2204 may be referred to as cross tees because these grid members aregenerally but not necessarily supported only by the longitudinal gridsupport members 2202 without hanger attachment to the overheadstructure.

Longitudinal and lateral grid support members 2202, 2204 are elongatedin shape having a length greater than their respective width (e.g. atleast twice), and in various embodiments lengths substantially greaterthan their widths (e.g. 3 times or more). Longitudinal grid supportmember 2202 may have a substantially greater length than lateral gridsupport member 2204 and form “runners” or “rails” which are maintainedin a substantially parallel spaced apart relationship by the lateralgrid support members. The lateral grid support members 2204 may beattached to and between adjacent (but spaced apart) longitudinal gridsupport members 2202 at appropriate intervals using any suitablepermanent or detachable coupling means. The combination ofinterconnected longitudinal and lateral grid support members 2202, 2204provides strength and lateral stability to the grid support system 2200.In one non-limiting example, the grid support system 2200 may be a metaldrywall grid system or suspended grid system available from ArmstrongWorld Industries.

In one embodiment, grid support members 2202 and 2204 may behorizontally oriented when installed. It will be appreciated, however,that other suitable mounted orientations of grid support members 2202,2204 such as angled or sloped (i.e. between 0 and 90 degrees tohorizontal) may be used. Accordingly, although support members 2202,2204 may be described in one exemplary orientation herein as horizontal,the invention is not limited to this orientation alone and otherorientations may be used.

Longitudinal and lateral grid support members 2202, 2204 intersect toform an array of grid openings 2208 which receive and essentially areclosed by ceiling tiles or panels 2300 when positioned within theopenings. In some embodiments, the grid support members 2202, 2204 maybe arranged in an orthogonal pattern wherein the support membersintersect at right angles (i.e. perpendicular) to form rectilinear gridopenings 2208 such as squares or rectangles (in top plan view).

The terminal ends 2205 of the lateral grid support members 2204 have endconnections configured for permanent or detachable connection to thevertical webs 2212 of the longitudinal grid support members 2202 atright angles to form a rectilinear grid pattern (see, e.g. FIGS. 34 and39). Non-limiting examples of suitable connection means includepermanent connection such as without limitation welding, soldering,etc., or detachable connection such as without limitation clips,brackets, threaded fasteners, interlocking tabs/slots, etc. Accordingly,the present invention is not limited by the manner of attachment orcoupling used. The terminal ends 2207 of the longitudinal grid supportmembers 2202 have end connections configured for permanent or detachableend-to-end connection to the terminal ends of adjoining longitudinalgrid support member to form continuous spans of the main beams (see,e.g. FIGS. 34 and 39). Similar permanent or detachable end connectionmeans as those described above may be used.

It will be appreciated that some lateral grid support members 2204 maybe run the same direction between and parallel to main beam longitudinalgrid support members 2202, as shown for example in FIG. 33. Accordingly,the lateral grid support members 2204 are not limited in their use toonly arrangement at right angles to the longitudinal grid supportmembers 2202.

FIG. 34 is a transverse cross-sectional view of a longitudinal gridsupport member 2202; the lateral grid support members 2204 having asimilar but not necessarily identical configuration in one embodiment.Referring to FIGS. 33 and 34, grid support members 2202, 2204 may beT-shaped (e.g. T-rails) in transverse cross section. The grid supportmembers have an inverted T-shaped configuration in an installed positionsuspended from an overhead building structure. Grid support members2202, 2204 may each include a longitudinally-extending horizontal bottomflange 2210, an enlarged top stiffening channel 2220, and a vertical web2212 extending upwards from the flange to the stiffening channel. Insome embodiments, the top stiffening channel 2220 may be omitted fromgrid support members 2202 and/or 2204.

The longitudinal and lateral grid support members 2202, 2204 each definea respective longitudinal axis 2LA and axial directions; the lateralgrid support members 2204 generally but not necessarily being arrangedtransversely thereto. In one implementation, bottom flange 2210 isoriented substantially horizontally when in an installed hung position(see, e.g. FIGS. 39 and 40) and has opposing portions which extendlaterally outwards from web 2212 and terminate in opposed axiallyextending longitudinal edges 2214. Web 2212 may be centered between theedges 2214 and vertically aligned with the vertical centerline 2CL1 ofthe grid support member in some embodiments. In other embodiments, theweb 2212 may be laterally offset from centerline 2CL1 of the gridsupport member 2202 or 2204 including being substantially aligned withone longitudinal edge 2214 of the grid support member 2202 or 2204forming a structural angle shape.

With continuing reference to FIGS. 33-35, the bottom flanges 2210 ofgrid support members 2202, 2204 each includes a downward facing bottomsurface 2206 that defines the “grid face” typically visible from theoccupied room or space below the grid support system 2200 if notconcealed. Bottom surface 2206 defines a horizontal ceiling referenceplane for the overhead grid support system 2200. Flange 2210 furtherdefines an upward facing top surface 2216, which in some embodiments maybe used for supporting a portion of the ceiling panels thereon.Longitudinal grid support members 2202 may be configured similarly orthe same as lateral grid support members 2204, or each may be different.Regardless of the configurations used for grid support members 2202 and,2204, each may include bottom flanges 2210 and downward facing flangesurfaces 2206 which preferably lie in the same horizontal plane in oneembodiment when hung from an overhead building structure. Furthermore, alower portion of the bottom flanges 2201 at the terminal ends 2205 ofthe of lateral grid support members 2204 may further be omitted whenfabricated or notched/cut off in the field. This facilitates flushmating with the longitudinal edges 2214 of longitudinal grid supportmembers 2202 and the adjoining grid faces at intersections betweenlongitudinal and lateral grid support members 2202, 2204 forming asubstantially continuous grid face.

Grid support members 2202, 2204 may be made of any suitable metallic ornon-metallic materials structured to support the dead weight or load ofceiling panels 2300 without undue deflection. In some non-limitingembodiments, the grid support members may be made of metal includingaluminum, titanium, steel, or other. In some non-limiting embodiments,the grid support members 2202, 2204 may be a standard heavy duty 15/16inch aluminum T-rail having a 15/16 inch grid face or 9/16 inch T-railhaving a narrow 9/16 inch grid face. Other types of grid support membersmay be used preferably with a sufficiently sized grid face for properlyfastening or attaching the ceiling panels thereto.

Features of the ceiling panels mountable on the foregoing ceilingsupport grid will now be described in further detail. Referringgenerally to FIGS. 35-41, a plurality of ceiling panels 2300 areattached to and supported by the grid support system 2200 in openings2208.

Ceiling panels 2300 may include grid-concealment features in oneembodiment being configured and dimensioned to hide or conceal at leasta portion of the ceiling support surface or grid face when mounted tothe longitudinal and lateral grid support members 2202, 2204 of the gridsupport system 2200. Accordingly, ceiling panels 2300 may be used toprovide a monolithic ceiling appearance which hides the ceiling supportor grid surface when viewed from the occupied building space createdbelow, as further described herein.

Referring now FIGS. 35-41, ceiling panels 2300 may have a generallyflattened body with a substantially greater horizontal width 2W1 andlength 2L1 than vertical thickness as shown. Ceiling panel 2300 has abody including a top surface 2302 facing upward toward the grid supportmember when mounted, an opposing bottom surface 2304, and peripheralsides 2306 extending therebetween along the perimeter of the ceilingpanel. Top and bottom surfaces 2302, 2304 may be generally planar andarranged substantially parallel to each other in one non-limitingembodiment. In the exemplary non-limiting embodiment shown, ceilingpanel 2300 has a rectangular shape having a length 2L1 and longitudinalperipheral sides 2306 b which are larger than width 2W1 and lateralperipheral sides 2306 a. In other embodiments, however, square ceilingpanels 2300 may be used.

For clarification, it bears noting that the ceiling panel shown in FIGS.36 and 38 is oriented so that top surface 2302 (normally hidden fromview in the interior space formed below the ceiling system) is facingdownward and the exposed bottom surface is facing upward for betterrevealing the edge details. This is opposite to the installed positionof the ceiling panels shown in FIGS. 39-41, in which the panel isinverted 180 degrees for mounting to the grid support system 2200 (i.e.top surface 2302 facing upwards and bottom surface 2304 facingdownwards).

In some embodiments, ceiling panels 2300 may have a rectilinear shape,such as without limitation square or rectangular. Each ceiling panel2300 includes four corners 2331 and peripheral edges 2332 extendingaround the perimeter of the panel. Edges 2334 define outward facingperipheral edge surfaces configured to interlock with adjoining ceilingpanels 2300 when mounted to the grid support system 2200, as furtherdescribed herein.

The ceiling panels 2300 are configured and dimensioned to hide the gridface of the overhead support grid 2209 (i.e. bottom surface 2206 of thegrid support members 2202 and 2204). Accordingly, referring to FIGS.33-41, ceiling panels 2300 each have a horizontal longitudinal length2L1 (measured parallel to longitudinal axis 2LA) which is larger thanthe corresponding horizontal longitudinal distance 2D1 (measuredparallel to longitudinal axis 2LA) between the inner longitudinal edges2214 (i.e. closest distance) of two adjacent albeit spaced apart gridlateral grid support members 2204. In some embodiments, ceiling panels2300 may each further have a horizontal lateral width 2W1 (measuredtransversely to longitudinal axis 2LA) which is larger than thecorresponding horizontal lateral distance D2 (measured transversely tolongitudinal axis 2LA) between the inner longitudinal edges 2214 (i.e.closest distance) of two adjacent albeit spaced apart grid longitudinalgrid support members 2202. In one embodiment, width 2W1 is substantiallyequal to distance D2 plus more than the width 2W2 of each of the twoflanges 2210 of the longitudinal grid support members 2202 which supportboth opposite longitudinally-extending peripheral sides 2306 of thepanel (see, e.g. FIGS. 33, 34, and 39) Similarly, in one embodiment,length 2L1 is substantially equal to distance 2D1 plus more than thewidth 2W2 of each of the two flanges 2210 of the lateral grid supportmembers 2204 which support both opposite laterally-extending sides 2306of the panel. In one implementation, one peripheral edge 2332 of eachceiling panel 2300 may terminate at a point coextensive with or beyondthe outermost longitudinal edge 2214 of the first of each pair ofadjacent but spaced apart longitudinal and lateral grid support members2202, 2204. The opposite peripheral edge 2332 of each ceiling panel 2300may terminate at a point coextensive with the vertical web 2212 of thesecond of each pair of adjacent but spaced apart longitudinal andlateral grid support members 2202, 2204.

Accordingly, when adjoining ceiling panels 2300 are installed in theoverhead support grid 2209 which are configured and dimensioned in theforegoing manner, the peripheral edge portions 2332 of the panelsoverlap and extend entirely beneath the flange bottom surfaces 2206 ofboth the two opposing longitudinal grid support members 2202 and twoopposing lateral grid support members 2204 surrounding each grid opening2208, thereby completely concealing the grid face. Perimeter regions oftop surface 2302 of each ceiling panel 2300 define upward facingsubstantially planar peripheral top surfaces 2335 which may eithercontact or fall in close proximity to bottom surfaces 2206 of gridsupport members 2202 and 2204 when the ceiling panel is mountedtherefrom (see, e.g. FIGS. 36, 39, and 40).

The ceiling panels 2300 may have a composite-structured hybridperipheral edge detail including a combination of a tongue-and-grooveand shiplap configurations. The hybrid edges of adjoining panels areconfigured to both interlock via the tongue-and-groove portion of theedge detail and hide the ceiling panel support surfaces or grid facesvia the shiplap portion of the edge detail.

Referring to FIGS. 35-41, each peripheral edge 2332 preferably but notnecessarily includes a shiplap portion comprising either an uppershiplap profile or feature 2340 adjacent top surface 2302 or a lowershiplap profile or feature 2350 offset and spaced verticallyapart/downward from the top surface of each panel 2300 (best shown inFIG. 41). The upper shiplap features of one ceiling panel 2300 has acomplementary configuration and arrangement to the lower shiplapfeatures 2350 on an adjoining panel so that the assembled shiplap edgesform a completed shiplap joint or seam when mutually engaged.

In one exemplary non-limiting embodiment as shown, each ceiling panel2300 may include two peripheral edges 2332 having a male upper shiplapfeature 2340 and two peripheral edges 2332 having a female lower shiplapfeature 2350. In one configuration, the upper shiplap features 2340 maybe formed on two orthogonally adjoining peripheral edges 2332 (i.e.oriented perpendicular to each other) which intersect at a first corner2331. Similarly, the lower shiplap feature 2350 may be formed on twoorthogonally adjoining peripheral edges (i.e. oriented perpendicular toeach other) which intersect at a second corner 2331 diagonally oppositeto the first corner 2331. The upper shiplap features 2340 may becontinuous in structure on the two adjoining peripheral edges 2332including at the first corner. Similarly, the lower shiplap features2350 may be continuous in structure on the two adjoining peripheraledges 2332 including at the second corner.

It will be appreciated that other arrangements of the shiplap featureson different peripheral edges may be used in other embodiments.Accordingly, the ceiling panel is not limited to the shiplap arrangementshown herein.

In one embodiment, each upper shiplap feature 2340 may be defined by acantilevered lateral extension 2341 of a respective first ceiling paneledge 2332 (reference FIGS. 35-41 with particular initial emphasis onFIG. 9 showing the disassembled shiplap joint of FIG. 40 between twoadjoining panels 2300 a, 2300 b). The top of the extension 2341 may beflush with and coextensive with the top surface 2302 of the main body ofthe ceiling panel 2300, thereby creating a continuous planar top surface2302. Other configurations may be used.

Upper shiplap feature 2340 includes a laterally outward facing upper endsurface 2342 and downward facing bottom surface 2344 arranged to engagea mating lower shiplap feature 2350 of an adjoining ceiling panel 2300.Bottom surface 2344 may be oriented substantially parallel to topsurface 2302 of ceiling panel 2300. In other embodiments, bottom surface2344 may be obliquely oriented to top surface 2302. The lateralextension 2341 preferably has a width sufficient to cover and at least aportion of the grid bottom flange 2210 (i.e. grid face or surface 2206)to which the ceiling panel is attached. In one embodiment, end surface2342 may be vertically aligned approximately with the web 2212 of thegrid support member 2202 or 2204 to which it attached (see, e.g. FIGS.39 and 40). In other embodiments, the end surface 2342 of lateralextension 2341 may align elsewhere on the flange 2210.

In one configuration, the lateral extension 2341 further defines amounting flange 2343 for attachment to the grid bottom flange 2210 (see,e.g. FIGS. 39 and 40). The mounting flange 2343 is configured andarranged for permanent or detachable engagement with grid flange 2210.Non-limiting examples of suitable attachment means include permanentjoining such as without limitation non-releasable adhesives, etc., ordetachable joining such as without limitation threaded fasteners 2380(shown), clips, brackets, interlocking tabs/slots, releasable adhesives,etc. If fasteners 2380 are used, mounting holes 2381 may be provided tofacilitate attaching the ceiling panel 2300 to the support grid. Theinvention is not limited in scope or applicability by the method used toattach the mounting flange to the grid support members.

With continuing reference to FIGS. 35-41, the lower shiplap feature 2350may be defined by an end recess 2351 formed in a respective secondceiling panel edge 2332. Lower shiplap feature 2350 includes ahorizontal upward facing seating surface 2352, laterally outward facingend surface 2355, and a vertical upper stop wall 2354 adjacent to thetop surface 2302 of ceiling panel 2300. Seating surface 2352 may beoriented substantially parallel to top surface 2302 of ceiling panel2300. In other embodiments, seating surface 2352 may be obliquelyoriented to top surface 2302. Seating surface 2352 of lower shiplapfeature 2350 is arranged to engage bottom surface 2344 of an uppershiplap feature 2340 when the ceiling panel joint is fully assembled, asshown in FIGS. 39 and 40.

Stop wall 2354 may be oriented perpendicular to and intersects topsurface 2302 of the ceiling panel 2300 at one end. At the other end,stop wall 2354 intersects and may be oriented perpendicular to seatingsurface 2352 as best shown in FIG. 41. In other embodimentscontemplated, stop wall 2354 may be obliquely oriented to the topsurfaces 2302 and 2352 of the ceiling panel 2300 and lateral extension2351, respectively. The stop wall 2354 is laterally/horizontal spacedinward and vertically offset from the end surface 2355 of the peripheraledge 2332. Stop wall 2354 may be oriented parallel to end wall 2355 insome embodiments. In other embodiments, stop wall may be obliquelyoriented to end wall 2355.

The tongue-and-groove portion of the ceiling panel edge detail will nowbe further described. In one embodiment, the peripheral edges 2332including a lower shiplap feature 2350 may further include a maleshiplap feature comprising a laterally outward projecting cantileveredtongue 2360 configured for insertion into a mating female shiplapfeature comprising a laterally open groove 2370 formed in an adjoiningceiling panel peripheral edge 2332 (see, e.g. FIGS. 40 and 41). The freeterminal end of tongue 2360 defines the peripheral edge end surface 2355of the ceiling panel. Tongue 2360 defines an edge recess 2361 and lowerstop wall 2362 disposed at and adjoining the bottom surface 2304. Stopwall 2362 is spaced laterally inwards from and vertically offset fromend surface 2355 of the ceiling panel edge. In one embodiment, the lowerstop wall 2362 is spaced inward from end surface 2355 by a distance lessthan the spacing between end surface 2355 and the upper stop wall 2354.In one embodiment, lower stop wall 2361 may be oriented parallel toupper stop wall 2354, and in further embodiments also parallel to endwall 2355. Other orientations including oblique may be used.

Lateral groove 2370 defines a recessed vertical stop wall 2371 arrangedto abut the tongue 2360 of an adjoining panel, and more particularly theend surface 2355 of the tongue as shown in FIG. 40. Stop wall 2371 islaterally offset inward and spaced apart from the end surface 2342 ofthe cantilevered lateral extension 2341. Stop wall 2371 limits theinsertion depth of the tongue into the groove. A laterally outwardfacing lower end surface 2372 adjoins the groove 2370 and bottom surface2304 of the ceiling panel 2300. In one embodiment, end surface 2372 islaterally offset inward and spaced apart from the top end surface 2342of the cantilevered lateral extension 2341. In one embodiment, endsurface 2372 is spaced inward from top end surface 2342 by a distanceless than the spacing between end surface 2372 and the recessed stopwall 2371. In one embodiment, lower end surface 2372 may be orientedparallel to upper end surface 2342, and in further embodiments alsoparallel to recessed stop wall 2371. Other orientations includingoblique may be used.

In one embodiment, the lateral extension 2341 (and mounting flange 2343defined by the extension) may have an L-shaped configuration as show inthe bottom plan view of FIG. 35. The lateral extension 2341 is thereforearranged on the perimeter of the ceiling panel on two adjacent andorthogonal peripheral edges 2332. In certain embodiments, the terminalends 2346 of the lateral extensions may have a length less than theperipheral edge 2332 on which it is disposed. Accordingly, the terminalends 2346 may be longitudinally or laterally offset from the parallelperipheral edges of an adjacent ceiling panel to form a corner space ornotch 2345 for receiving a portion of the lateral extension2341/mounting flange 2343 of an adjoining and interlocking panel (see,e.g. FIGS. 42 and 43).

The protruding tongue 2360 portions of the ceiling panels 2300 may havealso an L-shaped configuration in bottom plan view. The tongues 2360 mayhave a length substantially equal to the length of the peripheral edge2332 on which they are disposed (see, e.g. FIG. 35).

FIG. 39 shows ceiling panel joints formed with the hybrid edge detaildisclosed herein. This figure shows the ceiling panel joints formed onthe shorter peripheral sides 2306 a of a central ceiling panel 2300 b.Ceiling panel 2300 b is interlocked with two adjoining ceiling panels2300 a and 2300 c (shown hatched in cross-section for clarity) onopposite peripheral edges of ceiling panel 2300 b. FIG. 40 is a detailedview of the left joint; the right joint being similar. FIG. 41 is anexploded or disassembled view of the joint of FIG. 40.

Referring to FIGS. 39-40, one peripheral edge 2332 (left) of the centralceiling panel 2300 b is threadably fastened to a first lateral gridsupport member 2204 using the mounting flange 2343 defined by lateralextension 2341 of the upper shiplap feature 2340 and fasteners 2380.With respect to the shiplap portion of the hybrid edge details, theupper shiplap feature 2340 of ceiling panel 2300 b is seated on thelower shiplap feature 2350 of ceiling panel 2300 a such that bottomsurface 2344 of the upper feature is engaged with seating surface 2352of the lower feature. The seating surface 2352 defines a steppedconfiguration dimensioned to receive the upper shiplap feature 2350 sothat the top surfaces of adjoining ceiling panels 2300 are substantiallyflush with each other. End surface 2342 abuttingly contacts oralternatively may be disposed preferably at least proximate to upperstop wall 2354.

Advantageously, when the shiplap features of the ceiling panels 2300 a,2300 b are joined, the lower shiplap feature 2350 is arranged tocompletely conceal the otherwise exposed heads of the fasteners 2380,thereby eliminating the need to spackle or otherwise hide the head ofthe fastener for forming a monolithic ceiling appearance.

With respect to the tongue-and-groove portion of the hybrid edgedetails, tongue 2360 of ceiling panel 2300 a is inserted in and engagedwith lateral groove 2370 of ceiling panel 2300 b. End surface 2355 oftongue 2360 abuttingly contacts or alternatively may be disposedpreferably at least proximate to recessed stop wall 2371 in groove 2370to provide secure interlocked engagement between the adjoiningperipheral edges 2332 of each panel. Lower end surface 2372 of ceilingpanel 2300 b abuttingly contacts or alternatively may be disposedpreferably at least proximate to lower stop wall 2362 of ceiling panel2300 a.

It should be noted that the remaining peripheral edge 2332 (right) ofthe central ceiling panel 2300 b is supported only by tongue-and-grooveengagement with ceiling panel 2300 c, thereby eliminating the need tofasten this peripheral side 2306 of ceiling panel 2300 b to the supportgrid. The same joint configuration and arrangement as described above isused for joining the longitudinal peripheral sides 2306 b of ceilingpanel 2300 b to adjoining ceiling panels (see, e.g. FIGS. 42 and 43).Accordingly, the hybrid edge details according to the present disclosureallow each ceiling panel to be attached to a grid support member alongonly two of the four peripheral sides, thereby advantageously reducinginstallation time and costs.

Ceiling panels 2300 may be constructed of any suitable material orcombinations of different materials, which in certain embodimentspreferably have acoustical properties. Some non-limiting examples ofceiling panel materials that may be used include, without limitation,mineral fiber board, fiberglass, metals, polymers, wood, composites,combinations thereof, or other. Embodiments of ceiling panels 2300 havea sufficiently high noise reduction coefficient (NRC) and ceilingattenuation class (CAC) rating to be characterized as an acousticalsubstrate in contrast to gypsum-based drywall having substantially lowerNRCs (e.g. 0.05) characteristic of sound reflecting, not absorbingmaterials. NRC is a measure of sound energy absorption of a material. AnNRC rating of 0 is a perfect sound reflection material. An NRC rating of1 is a perfect sound absorption material. CAC is a measure for ratingthe performance of a ceiling material as a barrier to block airbornesound transmission through the material to/from the plenum above theceiling.

In some embodiments, ceiling panels 2300 according to the presentdisclosure may have an NRC of at least 0.50 and/or CAC of at least 230depending on the desired acoustical characteristics of the ceilingsystem. In a certain embodiment, the NRC rating may be at least 0.70.The shiplap and tongue-in-groove edge details may be formed by anyfabrication process or combination of processes capable of making thedetails. Non-limiting examples include cutting, routing, milling,casting, molding, etc.

In some embodiments contemplated, ceiling panels 2300 may be compositestructures formed from two or more separately formed layers or sheets ofmaterial which are bonded or joined together to form a complete panel.For example, referring to FIGS. 35-38 and 41 in a three layer/sheetconstruction, a top layer/sheet comprising the top surface 2302, uppershiplap feature 2340 and mounting flange 2343 could be one layer/sheet.A bottom layer/sheet comprising the bottom surface 2304 could be asecond layer/sheet. And a middle or core layer/sheet forming thetongue-and-groove features on opposing sides could be a thirdlayer/sheet. Any suitable method could be then used to join the sheetstogether, including as possible examples without limitation depending onthe layer/sheet materials used adhesive bonding, fasteners, welding,soldering, etc.

An exemplary method for installing a ceiling system that conceals theceiling support structure will now be described. In order to form amonolithic appearance for ceiling system 2100, the ceiling panels 2300are mounted and assembled in an alternating sequence using the mountingflanges 2342, and tongue-and-groove and shiplap edge details disclosedherein. FIGS. 42 and 43 are bottom plan views of exemplary ceilingpanels 2300 in a preassembly exploded view and assembled view,respectively.

The grid support system 2200 is first installed using a combination oflongitudinal and lateral grid support members 2202, 2204 in the mannerdescribed herein and shown in FIG. 33. For this exemplary method, itwill be assumed without limitation that the ceiling panels and the gridopenings 2208 are rectangular in shape. The same installationmethodology may be used if the ceiling panels were square.

The present method begins with first installing a row of ceiling panels2300 along the longitudinal direction between pairs of lateral gridsupport members 2204. For a suspended ceiling system, the grid supportmembers are first hung from an overhead building structure.Alternatively, in some embodiments, the grid support members may besurface mounted directly to the building structure, or alternatively thesurface of the building structure itself may be used for directattachment of the ceiling panels 2300 if the surface is sufficientlyflat. The present method, however, will be described for conveniencewithout limitation to a suspended-type ceiling system. The grid supportmembers 2202, 2204 are installed in an arrangement similar to FIG. 33with grid openings 2208 formed to receive ceiling panels 2300 therein.

Referring now to FIGS. 39-42, the method continues by now mounting theceiling panels. In step (1), a first ceiling panel 2300 c is centeredbelow a first grid opening 2208. The longitudinal and lateral mountingflanges 2343 of panel 2300 c (which includes upper shiplap feature 2340)are positioned beneath and then attached along two peripheral sides 2306to bottom flanges 2210 of intersecting longitudinal and lateral gridsupport members 2202, 2204 (see also FIG. 35). Fasteners 2380 may beused in one embodiment to secure the ceiling panel 2300 c to the gridsupport members. The mounting flange 2383 of ceiling panel 2300 c coversapproximately one-half the bottom grid surface 2206 (i.e. grid face) ofthe grid support member. The other half of the grid surface 2206 remainsexposed at this point in the ceiling installation process. The upper endsurface 2342 of the ceiling panel 2300 c is aligned approximately withthe vertical web 2212 of the grid support member. This ceiling panelwill now be used as the “base or foundation” panel for then sequentiallyinstalling the remaining ceiling panels, preferably in a predeterminedorder or sequence.

A second ceiling panel 2300 b is next installed in step (2) andconnected to ceiling panel 2300 c (see FIG. 10). The lateral tongue 2360on panel 2300 b is fully inserted into the lateral groove 2370 presentedbeneath the mounting flange 2343 of ceiling panel 2300 c alreadyattached to the support grid 2209. This supports the tongued lateralside of ceiling panel 2300 b, which itself is not attached directly tothe grid support member 2202 or 2204 (see, e.g. FIGS. 39-40). Thisassembly step also engages the lower slap feature 2350 formed abovetongue 2360 with the upper shiplap feature 2340 of ceiling panel 2300 c.

It bears noting that the foregoing single step (2) achieves severalobjectives. First, referring to FIG. 36 (showing joint similar inconfiguration to present joint formed between ceiling panels 2300 b and2300 c), the top surface 2302 of ceiling panel 2300 b covers theremaining previously exposed one-half of the grid support member bottomsurface 2206 to which mounting flange 2343 of ceiling panel 2300 c wasattached in step (1). The lower shiplap feature 2350 of ceiling panel2300 b covers the exposed head of fastener 2380. Preferably, the lowershiplap feature 2350 should have a length or lateral projectionsufficient to cover the fastener. Furthermore, a relatively narrow andtight seam or joint 2390 is formed between the bottom surfaces 2304 ofceiling panels 2300 b, 2300 c which lie in the same horizontal plane.This is intended to eliminate the need for applying joint compound orspackling to hide the seam which preferably is tight enough to beconcealed by application of the final finish coating or paint. Ifspackling is require, a single thin application would be sufficientwithout the need for taping the joint and successive iterations ofspackling and sanding typically encountered with wide drywall joints. Insome embodiments, slightly beveled or chamfered corner may be providebetween the bottom surface 2304 and peripheral sides 2360 along theentire perimeter of each ceiling panel to conceal any slightirregularities in the edges between adjoining ceiling panels.

Additional ceiling panels may then continue to be installed in the samelongitudinal row (direction) using the same process described and shownin steps (1) and (2). Following completion of the longitudinal row ofceiling panels, a second longitudinal row of laterally adjacent ceilingpanels is next illustrated in the present installation process. It willbe appreciated however that a full longitudinal row of ceiling panelsneed not be installed until adjacent longitudinal row ceiling panels canbe installed. Alternatively, lateral rows of ceiling panels may beinstalled first. Furthermore, various select sections of ceiling panelsmay be installed by mounting panels in the both the longitudinal andlateral directions, as illustrated below.

Referring now to FIGS. 39-42, ceiling panels located laterally adjacentto already installed ceiling panels 2300 b and 2300 c will be installednext. A third ceiling panel 2300 e is installed in step (3) which isconnected to previously-mounted ceiling panel 2300 c. The longitudinaltongue 2360 on panel 2300 e is fully inserted into the longitudinalgroove 2370 presented beneath the longitudinal mounting flange 2343 ofceiling panel 2300 c already attached to the support grid 2209. Thelongitudinal and lateral mounting flanges 2343 of panel 2300 e arepositioned beneath and then attached along two peripheral sides 2306 tobottom flanges 2210 of intersecting longitudinal and lateral gridsupport members 2202, 2204 (see also FIG. 3). Ceiling panel 2300 e isnow fully perimeter mounted and supported by both the support grid 2209and ceiling panel 2300 b. The longitudinal and lateral mounting flanges2343 of panel 2300 e are positioned beneath and then attached along twoperipheral sides 2306 to bottom flanges 2210 of intersectinglongitudinal and lateral grid support members 2202, 2204 (see also FIG.3). Panel 2300 e is now fully perimeter mounted and supported.

A fourth ceiling panel 2300 d may next be installed in step (4) byconnecting the panel to both previously-mounted ceiling panels 2300 band 2300 e. The longitudinal and lateral tongues 2360 of panel 2300 dare inserted into the longitudinal and lateral grooves 2370 of ceilingpanels 2300 b and 2300 e, respectively. The longitudinal and lateralmounting flanges 2343 of panel 2300 d are positioned beneath and thenattached along two peripheral sides 2306 to bottom flanges 2210 ofintersecting longitudinal and lateral grid support members 2202, 2204(see also FIG. 35). Panel 2300 d is now fully perimeter mounted andsupported. The process may be continued by mounting additional ceilingpanels either longitudinally or laterally adjacent to the installedpanel.

FIG. 43 shows the four installed ceiling panels 2300 b, 2300 c, 2300 d,and 2300 e. As illustrated by panel 2300 d, a portion of the mountingflanges 2383 of four panels contact the four grid support members 2202,2204 defining each grid opening of the ceiling support grid 2209. Viewedanother way, panel 2300 d is completely framed by the four mountingflanges.

It will be appreciated that ceiling panels preferably are installed inan order or sequence in which there is always a previously-mountedceiling panel having an exposed mounting flange 2343 available. This isbecause the mounting flanges cannot be fastened to the support grid 2209if there already is an installed panel covering the grid face due to theshiplap edge detail. Ceiling panels may be cut or otherwise factoryformed to allow installation along the perimeter of the ceiling system2100 adjacent the vertical walls of the building space where the normalinstallation method and sequence using the hybrid edge details cannot befully used.

According to further aspects of the invention, a multi-layered finalfacing system may be provided for ceiling panels 2300 which creates theexposed bottom surface of the ceiling system visible to room occupants.The facing system is intended and configured to preserve or enhance theacoustical properties (e.g. NRC, CAC, etc.) of the ceiling panelsubstrate.

Referring to FIG. 44, the facing system initially includes anappropriate treatment applied to the bottom surface 304 of the ceilingpanel substrate to prepare the surface for placement and properadherence or bonding of the final scrim layer or facing 2420 to thepanel. In some embodiments, the surface treatment layer 2400 applied tothe ceiling panel substrate may include coatings or facing with filled,unfilled, and/or painted nonwoven scrim. Examples of suitable surfacetreatment materials used may include, for example without limitation,non-woven fiberglass or polymeric scrim possessing sufficient inherentrepellency or filled, treated or coated scrim for repellency, typicallyin the thickness range of about and including but not limited to 0.010to 0.125 inches. Highly open coatings with a low air flow resistance(<100 mks Rayls) may be used to enhance sound absorption. The surfacetreatment layer 2400 may be applied in the factory or the field invarious implementations. The surface treatment may be beneficial for usein situations when the open nature of the acoustic substrate (panel)would readily absorb the adhesive applied in field applications. Thesurface treatment layer 2400 preferably provides sufficient hold out forthe adhesive (i.e. anti-penetration into the substrate) while allowingfor adhesion of the facing and acoustical performance

In some embodiments, the joints or seams 2390 formed between adjoininginterlocked ceiling panels such as shown in FIG. 44 may optionally betaped prior to application of the final facing if desired; however, thisis not necessary in all situations when using the final facing systemdescribed herein.

In one exemplary embodiment, the final facing layer 2420 is preferablybut not necessarily adhered to the hung treated ceiling panel substratein the field such as by use of a suitable adhesive. This allowsconcealment of the field-formed joints between 2390 between ceilingpanels 2300 after they are hung from the support grid 2209. The adhesivelayer 2410 is applied directly to the surface treatment layer 2400 usinga suitable thickness of adhesive to properly bond the final facing layer2420 to the treated substrate. In various embodiments, permanent orreleasable type adhesives may be used and applied by any suitable means(e.g. spraying, rolling, etc.). Suitable adhesives that may be used infield applications for adhesive layer 2410 include for example, withoutlimitation, a shear thinning adhesive with high wet tack such as used inwall paper (e.g. Roman Pro-880 clear strippable wallcovering adhesivefrom Roman Decorating Products or others). For pre-applied facing(factory applied finished face), an activated adhesive such as a hotmelt film may be used. Other suitable adhesives may include solvent orwater activated adhesives, pressure sensitive adhesive tapes, or appliedpolymer emulsion adhesives.

The final facing 2420 provides the aesthetic look and the appropriateacoustical characteristics for the specified application. In someembodiments, suitable materials that could be used for facing 2420 arenonwoven (glass filled or pre-painted), fabric, or perforated materials.Other suitable facing materials include fiberglass or polymericnon-wovens (filled or unfilled/finished or unfinished), fabrics, orperforated films. Exemplary non-limiting thicknesses that may be usedfor the final facing material are thicknesses in a range from about andincluding 0.010 to 0.150 inches. The limiting factors on types andthicknesses of facing materials used include economics, acoustics, andfinal visual appearance.

Depending on the type of facing product used, facing 2420 may beembodied in sheets or rolls of material for application to the ceilingpanels in the field. In some non-limiting examples, rolls of facing 4feet in width may be provided.

The facing 2420 may have a rectilinear shape in some embodiments. Incertain non-limiting exemplary embodiments, the final facing 2420 mayhave a width larger than at least one of the width 2W1 and length 2L1 ofthe ceiling panels 2300. The facing 2420 may also have a length (thedimension perpendicular to the width of facing) larger than at least oneof the width 2W1 and length 2L1 of the ceiling panels 2300. In someembodiments, the length of the facing 2420 is larger than both the width2W1 and length 2L1 of the ceiling panels 2300.

An exemplary method for facing a ceiling system in the field (i.e.jobsite) to create a monolithic appearance will now be described withreference to FIGS. 13-15. These figures show sequential bottom planviews of the ceiling system 2100 during application of the final facing2420. The grid support system 2200 and ceiling panels 2300 are firstinstalled using the mounting flanges 2342, and tongue-and-groove andshiplap edge details as already described above and shown in FIGS. 42and 43.

In this exemplary method, it will be assumed for convenience withoutlimitation that the array of ceiling panels 2300 are arranged in arunning bond pattern with offset staggered lateral joints 2390 betweenadjacent longitudinal rows of ceiling panels as shown in FIG. 45. Theceiling panels 2300 may each measure 2 feet wide by 8 feet long in thisnon-limiting example with the support grid 2209 having grid openings2208 sized commensurately. As seen, a plurality of longitudinal jointsis formed between laterally adjoining peripheral edges of the ceilingpanels 2300. Similarly, a plurality of lateral joints is formed betweenlongitudinally adjoining peripheral edges of the ceiling panels. At thisjuncture in the facing process, the longitudinal and lateral joints 2309between ceiling panels are still visible.

The facing process begins by first applying a surface treatment layer2400 to the bottom surfaces 2304 of the ceiling panels before bondingthe final facing 2420 thereto. This prepares the surfaces for adhesivemounting of the facing. In some embodiments, depending on the ceilingpanel material used, the surface treatment may not be needed to properlybond the facing to the ceiling panel in which case the treatment may beomitted.

An adhesive layer 2410 is next applied to the treated bottom surface2304 of the ceiling panels 2300. To ensure maximum adhesive strength forbonding the facing 2420 to the ceiling panels, the adhesive and facingmay be applied to the ceiling panels working a section or region at atime to prevent excessive drying out of the adhesive.

The final facing 2420 which will be visible to room occupants is nextapplied. The facing 2420 may be provided in a variety of sizes andformats (e.g. rolls, sheets, etc.). Preferably but not necessarily, thefacing 2420 has a continuous uninterrupted length in some embodimentssubstantially greater than the length 2L1 or width 2W1 of any individualceiling panel. This allows the facing 2420 to cover the bottom exposedsurface area of a plurality of ceiling panels 2300 (see, e.g. FIGS. 46and 47). In this non-limiting example, the facing 2420 may be 4 feetwide and may be provided in roll form with the length of the facingbeing substantially greater than the width. Any length or width of finalfacing may be provided in roll form with the length and width beingdetermined by the design and jobsite requirements, and handlingconsiderations. Non-roll form sheets final facing of any suitable lengthand width may alternatively be used.

The facing 2420 will be run in a lateral direction in this example (fromleft to right in FIG. 45); however, in other embodiments the facing berun in the longitudinal direction (from top to bottom in FIG. 13). Inother embodiments, the facing 2420 may be run in diagonal directions atan oblique angle to the longitudinal and lateral directions.

The desired length of facing 2420 is first measured and then cut fromthe roll such as with a utility knife.

With the adhesive layer already applied to a section of the hung ceilingpanels (comprising part or all of the bottom surfaces 2304 of multiplepanels), a first lateral row of final facing 2420 is adhesively bondedto the treated or untreated bottom surfaces 2304 of ceiling panels asshown in FIG. 46. The facing 2420 spans across and conceals multipleportions of the longitudinal joints 2390 (represented by dashed linesbeneath the facing). In this non-limiting example, the facing 2420 has alength equal to the combined widths 2W1 of 12 ceiling panels. The facingin this non-limiting example also falls directly on or near multiplelateral offset joints as seen along the top peripheral edge of thefacing thereby partially or completely concealing those joints. In otherembodiments contemplated, facing 2420 with a larger width than 4 feetused in this non-limiting example (e.g. 5 or 6 feet) may be used whichwould cover additional lateral joints completely.

Second and additional lateral rows of facing 2420 are applied to theremaining ceiling panels 2300 in a similar manner until the entireexposed bottom surfaces 2304 of the ceiling panels are covered, as shownFIG. 47. Preferably, the seams formed between adjoining peripheral edgesof rows of facing are abutted as tightly as possible to minimize anygaps therebetween and their visibility.

The final facing 2420 results in a plurality of laterally extendingseams formed between adjoining lateral rows facing. This results in afew number of facing seams than the multiple longitudinal and lateraljoints 2390 between the ceiling panels 2300. Advantageously, the finalfacing 2420 with extremely sharp and straight peripheral edges generallyallows creation of tighter and narrower seams between adjoining sheetsof facing (somewhat analogous to seams between adjoining sheets or runsof wallpaper). These narrow seams are less visually noticeable thanjoints 2390 between adjoining ceiling panels 2300, thereby creating amonolithic ceiling appearance. If the facing 2420 is a paintable type,the finish coat of paint may entirely fill and conceals any seamsbetween the rows or sheets of facing.

It will be appreciated that the joints 2390 between adjoining ceilingpanels 2300 are covered by a single uninterrupted length of facing 2420which bridges the joints, rather than by applying joint compound tape ora similar material thereby avoiding the use of joint compound altogetherfor purposes of concealing the joints. Accordingly, the faced ceilingsystem 2100 with monolithic ceiling appearance described hereinadvantageously may be installed without use of any joint or spacklingcompound.

Although ceiling panels 2300 are disclosed herein in one non-limitingembodiment as having a hybrid peripheral edge detail, it will beappreciated that other types of edge details and combinations ofdifferent type edge details may be used including edge details such aswithout limitation butt-joint, shiplap, tongue-and-groove, etc. Thepresent invention is therefore not limited to panels having hybrid edgedetails alone.

While the foregoing description and drawings represent exemplaryembodiments of the present disclosure, it will be understood thatvarious additions, modifications and substitutions may be made thereinwithout departing from the spirit and scope and range of equivalents ofthe accompanying claims. In particular, it will be clear to thoseskilled in the art that the present invention may be embodied in otherforms, structures, arrangements, proportions, sizes, and with otherelements, materials, and components, without departing from the spiritor essential characteristics thereof. In addition, numerous variationsin the methods/processes described herein may be made within the scopeof the present disclosure. One skilled in the art will furtherappreciate that the embodiments may be used with many modifications ofstructure, arrangement, proportions, sizes, materials, and componentsand otherwise, used in the practice of the disclosure, which areparticularly adapted to specific environments and operative requirementswithout departing from the principles described herein. The presentlydisclosed embodiments are therefore to be considered in all respects asillustrative and not restrictive. The appended claims should beconstrued broadly, to include other variants and embodiments of thedisclosure, which may be made by those skilled in the art withoutdeparting from the scope and range of equivalents.

1.-65. (canceled)
 66. A method for facing a ceiling system, the methodcomprising: mounting an orthogonal array of ceiling panels to ceilingsupport structure, each ceiling panel including a width, a length, topand bottom surfaces, a pair of opposed longitudinal peripheral edges,and a pair of opposed lateral peripheral edges; forming a plurality oflongitudinal joints between laterally adjoining peripheral edges of theceiling panels; and bonding a final facing to the bottom surfaces of theceiling panels, the facing having a continuous length in at least onedirection covering and concealing the plurality of the longitudinaljoints, wherein the facing has a width larger than at least one of thewidth and length of the ceiling panels.
 67. The method according toclaim 66, further comprising forming a plurality of lateral jointsbetween longitudinally adjoining peripheral edges of the ceiling panels,wherein the facing has a continuous extent that at least partiallycovers and conceals the plurality of the lateral joints.
 68. The methodaccording to claim 66, wherein the facing has a thickness less than thethickness of the ceiling panels.
 69. The method according to claim 66,further comprising applying a surface treatment to the bottom surfacesof the ceiling panels before bonding the final facing.
 70. The methodaccording to claim 69, wherein the bonding step comprises applying anadhesive layer to the treated bottom surfaces to bond the final facingto the ceiling panels.
 71. The method according to claim 66, wherein thebonding step comprises applying an adhesive layer to the bottom surfacesof the ceiling panels to bond the final facing to the ceiling panels.72. The method according to claim 66, wherein the peripheral edges ofthe ceiling panels having a hybrid edge detail including atongue-and-groove portion and a shiplap portion.
 73. A retaining clipattachable to a grid support member of a ceiling system for supporting aceiling tile, the retaining clip comprising: a longitudinal axis; aplanar mounting base configured for embedded attachment in the ceilingtile, the mounting base; opposing recurvate ends located at oppositeends of the mounting base, the recurvate ends each defining anengagement protrusion extending outwards transversely to thelongitudinal axis, a bottom section of the mounting base extendinghorizontally between the recurvate ends; a pair of longitudinallyextending opposing upright mounting wings configured for lockingengagement with the grid support member, the mounting wings extendingupwards from the recurvate ends of the mounting base and being spacedapart to define an upwardly open cavity configured to receive the gridsupport member at least partially therein; the mounting wings beingresiliently deformable and transversely movable between undeflected anddeflected positions; and a locking feature disposed on each mountingwing extending into the cavity and arranged to engage a top surface ofthe grid support member when in a mounted position.
 74. The retainingclip of claim 73, wherein: the retaining clip includes a narrowed throatportion disposed between top edges of the mounting wings and therecurvate ends of the mounting base; each locking feature is disposedbetween the top edge of a respective mounting wing and the narrowedthroat portion of the retaining clip; each locking feature is disposedbetween opposing axial ends of a respective mounting wing; and eachrecurvate end defines an outer top surface arranged parallel to thebottom section of the mounting flange in vertically spaced apartrelationship.
 75. The retaining clip of claim 74, wherein the retainingclip includes a top opening configured and dimensioned to receive aportion of the grid support member therethrough, and the narrowed throatportion has a width less than the grid support member.
 76. Afactory-fabricated ceiling panel comprising: a panel body comprising atop surface, a bottom surface, a first panel edge extending between thetop and bottom surfaces, and a second panel edge extending between thetop and bottom surfaces, the first panel edge being opposite the secondpanel edge; and a facing sheet coupled to the panel body by afactory-applied adhesive, the facing sheet comprising a first flaphaving a portion that protrudes beyond the first panel edge and a secondflap having a portion overlying the bottom surface and adjacent thesecond panel edge that is not adhered to the panel body.
 77. The ceilingpanel of claim 76, wherein the first flap terminates in a first sheetedge spaced a first distance from the first panel edge; wherein thesecond flap terminates in a second sheet edge spaced inward from thesecond panel edge by a second distance; and wherein the first distanceis greater than the second distance.
 78. The ceiling panel of claim 76,wherein the second flap protrudes beyond the second panel edge.
 79. Theceiling panel of claim 78, wherein the first flap further comprises aportion overlying the bottom surface and adjacent the first panel edgethat is not adhered to the panel body.
 80. The ceiling panel of claim76, wherein the panel body comprises a third panel edge extendingbetween the top and bottom surfaces, and a fourth panel edge extendingbetween the top and bottom surfaces, the third panel edge being oppositethe fourth panel edge, the third and fourth panel edges intersecting thefirst and second panel edges, wherein the facing sheet comprising athird flap having a portion that protrudes beyond the third panel edge.81. The ceiling panel of claim 80, wherein the facing sheet comprises afourth flap having a portion that protrudes beyond the fourth paneledge.
 82. The ceiling panel of claim 76, wherein the panel bodycomprises sound-absorbing material selected from the group consisting ofmineral fiber board, fiberglass, jute fiber, wood, and composites. 83.The ceiling panel of claim 76, wherein the facing sheet compriseslaminated non-woven glass fibers.